Jhagadia Copper Limited (JCL) is the largest producer of LME Grade “A” Copper Cathodes in India using secondary smelting route. Experiencing productivity and efficiency loss due to excessive heating of refractory lining, the company approached TCS Innovation Labs – Tata Research Development and Design Centre (TRDDC) to address the problem. Drawing from its prior experience in delivering model-based solutions towards energy efficient steel refining and gas fired boiler operation, TRDDC delivered a unique solution for JCL’s complex copper smelting process. TRDDC proposed a model based optimization of JCL’s Kaldo furnace resulting in a new furnace operating regime. The solution has improved productivity by 10% and the refractory life by 50-60%, leading to direct cost savings.