Numerical and experimental studies on the heat transfer characteristics and process optimization of the billet soaking furnace

•Mathematical model can be monitored online in real time.•Relative error of mathematical model within ±5 %.•Optimization strategy saves 24% of heating time. The precision of furnace temperature control in the soaking furnace is critical to the quality of billet heating. This paper develops a three-dimensional(3D) mathematical model of the heating process of steel billets in the soaking furnace, which can be monitored online in real time. The accuracy of the model was verified by black-box experiments. A comparative analysis of the model’s simulated and experimental data revealed a hit rate exceeding 70 % (with a relative error margin within ± 5 %). Leveraging this mathematical model, we propose a direct optimization strategy that effectively saves 24 % of heating time, accelerates the process of achieving temperature uniformity within the billet, and boosts overall heating effectiveness. This approach offers potential for broader application in optimizing the heating processes of various materials.