In the field of non-ferrous metal smelting, the energy efficiency and environmental protection
level of the roasting process directly determine the competitiveness of production. As a new
generation of intelligent equipment, flashing roaster is reshaping the technical boundary of
traditional roasting process by integrating electromagnetic field regulation and thermodynamic
optimization. In this paper, we will analyze its core technology principles, analyze the application
scenarios in the automation upgrade, and provide reference paths for the intelligent
transformation of the industry.
The technical core of the flash roaster
The core of flash magnetic roaster is different from the traditional roasting equipment, lies in
its unique “magnetic - heat - flow” multi-field coupling control system. The system through
the high-frequency alternating magnetic field (50-100kHz) and precise temperature control
synergistic effect, to achieve material activation and pyrolysis process optimization in depth.
1. Dynamic magnetic field control technology
The furnace body adopts modular electromagnetic generator group, which can adjust the magnetic
field strength (0.5-3T) and frequency in real time according to the material characteristics.
Experimental data show that when the magnetic field gradient reaches 200T/m, the surface
activation energy of sulfide minerals is reduced by 40%, which significantly improves the
oxidation reaction rate.
2. Three-dimensional thermal field coupling design
Through the microwave radiation unit (2.45GHz) and infrared temperature control probe arranged in
a ring, a uniform thermal field with axial temperature gradient ±2℃/m and radial temperature
difference <5℃ is constructed. Compared with the traditional rotary kiln, the thermal efficiency is
increased to 82% and gas consumption is reduced by 35%.
3. Intelligent material flow system
Pneumatic conveying device cooperates with electromagnetic vibrating fabricator to realize
feeding accuracy ±0.5kg/min. In the case of copper concentrate roasting, the material
residence time is compressed from 120 minutes to 45 minutes, and the sulfur removal
rate is stabilized at more than 98.5%.
Four application scenarios for automation upgrade
Scenario 1: Adaptive production of complex ore materials
Multi-metal mixed ore processing: real-time detection of the composition of the materials
entering the furnace through the XRF online analyzer, and automatic matching of the magnetic
field-temperature curve. After being applied by a copper smelting enterprise, the sulfur
residue of roasting sand is controlled to be below 0.3% when processing complex copper
concentrates containing 3% arsenic.
Adaptive adjustment of particle size: The laser particle sizer is linked with electromagnetic
vibrating screen to increase the processing efficiency of 3-15mm particle size interval by 40%.
Scenario 2: Intelligent process control
Digital twin system: establish a three-dimensional simulation model of the furnace body,
synchronize the actual working condition data every 30 seconds, and the prediction deviation
rate is <1.2%.
Self-searching optimization algorithm: temperature control strategy based on Deep
Reinforcement Learning (DRL) narrows the fluctuation range of energy consumption in the
roasting section from ±8% to ±2.5%.
Scenario 3: Closed-loop environmental protection management
Synergistic treatment of sulfur fumes and dust: pulse electric dedusting + ionic liquid
desulfurization tower is integrated at the flue gas outlet, with sulfur dioxide capture efficiency
reaching 99.8% and particulate matter emission <10mg/Nm³.
Waste heat gradient utilization: middle and low temperature waste heat (200-350℃) is used
for power generation, and the high temperature section (above 600℃) is fed back to the
drying process, which increases the comprehensive energy utilization rate by 28%.
Scenario 4: Equipment health management
Electromagnetic coil life prediction: Through vibration spectrum analysis + coil impedance
detection, it warns of failure risk 14 days in advance.
Intelligent maintenance system: AR glasses guide maintenance personnel to locate fault
points, reducing maintenance time by 60%.
Three major breakthrough directions for industry change
Breakthrough 1: Process parameter limit expansion
The processing temperature range is expanded from the traditional 650-850℃ to 400-950℃,
which is compatible with a variety of materials such as zinc roasting sand and nickel-cobalt ore.
The processing capacity of single equipment breaks through 800 tons/day, which is 2.3 times
higher than that of traditional equipment.
Breakthrough 2: Production Flexibility Upgrade
Developing modular furnace structure, switching between copper smelting mode
and lead-zinc mode is completed within 3 hours.
Load regulation response time <15 seconds, adapting to the fluctuating power supply
demand of new energy grid.
Breakthrough 3: In-depth mining of data value
Construction of process knowledge map: accumulated 100,000 sets of working condition
data and formed 128 key parameter optimization models.
Quality traceability system: 137 process parameters of each batch of roasted sand are
recorded through blockchain technology, meeting the requirements of ISO 14067
carbon footprint certification.
Quantitative Analysis of Economic Benefits and
Environmental Protection Value
1. Cost structure optimization
Reduction of labor cost: the automation of the whole process reduces the number
of operators from 12 to 3 per shift.
Energy consumption index: the comprehensive energy consumption of tons of ore has
been reduced to 58kgce, which is 32% lower than the industry access standard.
Precious metal recovery: gold and silver capture rate increased to 99.2%, with an annual
efficiency increase of more than 12 million yuan (calculated on the basis of 100,000
tons production capacity).
2. Environmental Benefit Assessment
Carbon emission reduction: carbon dioxide equivalent emission per ton of roasted
sand is reduced from 320kg to 210kg.
Hazardous waste reduction: Arsenic dregs generation is reduced by 65%, saving 4 million
RMB per year in hazardous waste disposal fees.
Water recycling: cooling water recycling rate reaches 95%, new water consumption reduced by 80%.
Future Technology Evolution Trends
1. Intelligent deep integration
Developing 5G+MEC edge computing platform, compressing the delay of control instructions to 8ms.
Introducing machine vision technology to realize millimeter-level identification of
abnormal working conditions such as knots and tumors.
2. New energy coupling innovation
Experimenting with direct-drive photovoltaic power supply mode, increasing the
proportion of green power to 40%.
Development of hydrogen roasting technology, replacing 30% of natural gas
consumption with hydrogen.
3. Expanded application of special materials
E-waste treatment: development of low-temperature magnetron roasting model for
circuit board precious metal recovery.
Strategic metal extraction: customized roasting solutions for rare earth ores and lithium pyroxene.
Conclusion
The technological breakthrough of flash magnetic roaster marks that non-ferrous metal smelting
has entered a new era of “magnetic control intelligent roasting”. Through the precise control of
physical field and the deep integration of industrial Internet, it not only solves the chronic problems
of high energy consumption and heavy pollution of traditional roasting process, but also opens up
the infinite possibilities of digital reengineering of production process. Driven by the goal of
“double carbon”, the popularization and application of this technology will become the core
engine of the green transformation of the non-ferrous industry, and boost China's metallurgical
equipment towards the high-end of the global value chain.