Abstract: This paper presents SmartFurnace IoT, an intelligent system designed for real-time monitoring and predictive maintenance of Direct Reduced Iron (DRI) kilns. It integrates temperature, gas, and material flow sensors with edge devices and cloud-based AI algorithms to enhance safety, reduce downtime, and improve energy efficiency. The system provides live dashboards, automated alerts, and historical data logging, enabling proactive interventions and pollution control compliance. The approach targets cost-effective modernization of sponge iron plants, particularly in industrial regions like Odisha and Chhattisgarh.