Case Study: Optimising Thermal Performance with Computational Modelling
FISC is working with industry to help them solve problems relating to six key themes. In this case study partner Lucideon is driving energy efficiency through advanced modelling and data science.
FISC theme: Process Optimisation
Designing and improving systems to minimise process variability, maximise resource utilisation and identify best practice. Data gathered will be analysed to help improve operations, but also to identify best practice across the foundation industries and transfer knowledge that aids the competitiveness of the UK.
What problem/s does industry have?
Ceramic manufacturing is inherently energy-intensive, with firing processes consuming significant amounts of gas or electricity. Continuous kiln operation makes experimental optimisation difficult, often leaving manufacturers locked into inefficient practices that drive up costs and carbon emissions.
How is FISC helping solve the problem/s?
Through the IMPACT programme, the Applied Materials Research, Innovation and Commercialisation Company (AMRICC) at Lucideon, deployed its unique combination of materials science expertise and advanced computational tools to tackle this challenge. Using physics-based thermodynamic modelling, the team created accurate digital representations of industrial kilns—both gas-fired and electric—capturing temperature distribution and heat transfer dynamics. This enabled manufacturers to identify opportunities to lower kiln set-point temperatures without compromising product quality, unlocking substantial energy savings.
Complementing this, AMRICC's data science team implemented sensor-based monitoring and machine learning analytics to pinpoint inefficiencies in real-world operations. For example, analysis of zone temperature oscillations revealed that minor adjustments to firing profiles could reduce excess gas consumption and stabilise thermal performance.
How does this benefit industry?
Energy Savings Computational modelling demonstrated that optimised firing profiles could save hundreds of thousands of pounds annually in energy costs, with one of the use cases showing a reduction of 4% of the energy demands, simply from optimisation.
Carbon Reduction Lower set-point temperatures and improved process control directly reduce greenhouse gas emissions, supporting manufacturers' net-zero ambitions.
Operational Insight Real-time data capture and analysis provided actionable intelligence, enabling manufacturers to fine-tune processes without costly trial-and-error experimentation.
Role of FISC
This project exemplifies the critical role of Research and Technology Organisations (RTOs) like AMRICC in accelerating industrial decarbonisation. By combining deep materials science knowledge with advanced modelling and data analytics, AMRICC bridges the gap between theoretical innovation and practical implementation—delivering solutions that are both scientifically robust and commercially viable.
If you'd like FISC to support you with your industrial problems please drop us an email at info@ukfisc.org
Published: 09-12-2025
Latest - Impact
You may have noticed that Lucy and I are slowly moving away from using the term Foundation Industries, and more often than not referring to the collective of the metal, chemical, paper, glass, ceramics, and cement industries as the Foundational Industries.
Let's be honest, when we talk about innovation in the foundational industries, the conversation often jumps straight to tech; new processes, low-carbon materials, AI-driven optimisation. But here's the thing, none of it scales without people. From ideation to implementation, the scale-up and commercialisation of sustainable technologies in these sectors depend on human ingenuity, cross-sector collaboration, and leadership.
When taking over as Co-Directors of FISC, Sarah and I wanted to address the values of the consortium and align them to our own values and the needs of the industries that we serve. To become the voice of innovation across the foundational industries, we have to make sure that every voice is heard. So we made "People Powered Progress" one of our three core values.
What do you think of when you hear the word innovation? A shiny new technology? A clever app? A robot doing something fancy? In some cases, that's true, but for the foundational industries innovation often takes the shape of a new material formulation or a new conversion process; innovation is not always visible, but it has a big impact. That impact needs to be measurable, scalable, and game-changing to support the journey to net zero.
When taking over as Co-Directors of FISC, Lucy and I made "Impactful Innovation" one of our three core values, aiming to challenge the status quo and find bold, industrially focused solutions that actually move the needle on sustainability.
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