Russia Creates a Digital Twin of a Metallurgical Furnace
Researchers in Novosibirsk have developed the first digital replica of an industrial electric furnace in Russia and the CIS—an innovation that trains workers and helps prevent costly accidents.
Scientists at Novosibirsk State Technical University (NSTU) have created the country’s first digital twin of industrial electric furnaces, a technology designed to train metallurgical plant personnel in emergency scenarios within a fully virtual and safe environment. The system helps prevent expensive breakdowns and production downtime.
According to NSTU’s press service, the platform is an exact digital replica of real industrial furnaces. Using VR headsets, up to 15 employees can operate simultaneously in a shared virtual workshop. The system, powered by neural networks that have analyzed thousands of scenarios, acts as an intelligent assistant—guiding users through complex and critical situations.
The key advantage of the technology lies in its ability to protect production and reduce costs. It functions as a next-generation training simulator that prepares staff for emergencies without risking human safety or damaging valuable industrial assets.
The program was developed in just one year, based on technical blueprints and datasets collected by one of the industry’s leading companies over a 15-year period.
Researchers emphasize that the platform serves as a ready-made tool for the digital transformation of heavy industry. It enables engineers to create virtual models of complex equipment—ranging from crushers to mills—within a few months.
The system has already been deployed at several Russian plants and is being prepared for rollout in Kazakhstan and other manufacturing sites. In the future, developers plan to link the digital twin to real furnaces for automatic process control, maintenance scheduling, and repair planning.
