Experience with Digital Process
Optimization of Zinc Roasting Plants
Robert Schiemann, Steffen Haus, Marcus Runkel and Jörg Hammerschmidt
Abstract Operation of zinc roasting plants has always been a challenge for changing feed mixtures and difficult concentrate qualities. Especially very fine particle
sizes and increased amount of impurities like Pb and Cu require a higher attention
of the control room operator to run the plant in stable conditions. As a result of this
manual roasting plant control, the operation campaigns get interrupted by unplanned
shutdowns due to poor roaster bed fluidization. In addition, the production targets and
product quality are difficult to reach. Therefore, plant availability becomes more of
a focus than other key production indicators (KPI). Operating the complete process
chain consisting of zinc roasting furnace-gas cleaning and acid plants in desirable
operating conditions is subject to many factors such as feed, air, and oxygen flow as
well as water addition at different positions and many more. Operating the roaster in
a stable and profitable operating window requires careful, regular, and anticipatory
adjustment of these parameters. To support the operation of such plants, Outotec has
developed and commissioned the Pretium Roaster Optimizer, a system that continuously leverages embedded process know-how to operate the roaster in an optimal
way for high process efficiency, a consistently high product quality and improved
economical KPIs. This chapter gives a short review on the application of modern
advanced automation and optimization methods to improve metallurgical process
plant operations and in specific the zinc roasting process.
Keywords Roasting · Digitalization · Zinc · Digital know-how
R. Schiemann (B) · S. Haus · J. Hammerschmidt
Outotec GmbH & Co. KG, Ludwig-Erhard-Straße 21, 61440 Oberursel, Germany
e-mail: robert.schiemann@outotec.com
S. Haus
e-mail: steffen.haus@outotec.com
J. Hammerschmidt
e-mail: joerg.hammerschmidt@outotec.com
M. Runkel
Outotec (USA) Inc., 8280 Stayton Dr. Ste. M, Jessup, MD 20794, USA
e-mail: marcus.runkel@outotec.com
© The Minerals, Metals & Materials Society 2020
A. Siegmund et al. (eds.), PbZn 2020: 9th International Symposium
on Lead and Zinc Processing, The Minerals, Metals & Materials Series,
https://doi.org/10.1007/978-3-030-37070-1_33
377
Optimization of Zinc Roasting Plants
Robert Schiemann, Steffen Haus, Marcus Runkel and Jörg Hammerschmidt
Abstract Operation of zinc roasting plants has always been a challenge for changing feed mixtures and difficult concentrate qualities. Especially very fine particle
sizes and increased amount of impurities like Pb and Cu require a higher attention
of the control room operator to run the plant in stable conditions. As a result of this
manual roasting plant control, the operation campaigns get interrupted by unplanned
shutdowns due to poor roaster bed fluidization. In addition, the production targets and
product quality are difficult to reach. Therefore, plant availability becomes more of
a focus than other key production indicators (KPI). Operating the complete process
chain consisting of zinc roasting furnace-gas cleaning and acid plants in desirable
operating conditions is subject to many factors such as feed, air, and oxygen flow as
well as water addition at different positions and many more. Operating the roaster in
a stable and profitable operating window requires careful, regular, and anticipatory
adjustment of these parameters. To support the operation of such plants, Outotec has
developed and commissioned the Pretium Roaster Optimizer, a system that continuously leverages embedded process know-how to operate the roaster in an optimal
way for high process efficiency, a consistently high product quality and improved
economical KPIs. This chapter gives a short review on the application of modern
advanced automation and optimization methods to improve metallurgical process
plant operations and in specific the zinc roasting process.
Keywords Roasting · Digitalization · Zinc · Digital know-how
R. Schiemann (B) · S. Haus · J. Hammerschmidt
Outotec GmbH & Co. KG, Ludwig-Erhard-Straße 21, 61440 Oberursel, Germany
e-mail: robert.schiemann@outotec.com
S. Haus
e-mail: steffen.haus@outotec.com
J. Hammerschmidt
e-mail: joerg.hammerschmidt@outotec.com
M. Runkel
Outotec (USA) Inc., 8280 Stayton Dr. Ste. M, Jessup, MD 20794, USA
e-mail: marcus.runkel@outotec.com
© The Minerals, Metals & Materials Society 2020
A. Siegmund et al. (eds.), PbZn 2020: 9th International Symposium
on Lead and Zinc Processing, The Minerals, Metals & Materials Series,
https://doi.org/10.1007/978-3-030-37070-1_33
377