Recent developments in digitalization for minerals and metals processing have increasingly shifted the focus from new plant constructions towards optimization of existing operations. Owners of roaster plants are looking into maximizing throughput and efficiency with the installed equipment. Outotec has introduced the Roaster Optimizer in several production sites, a digital system allowing 24/7 operational and personal expert support when required. The system comprises process optimization schemes, process modelling and advisory information in one digital solution. Success of this Optimization system is measurable in terms of lower emissions, increased throughput as well as enhanced control of process conditions to improve product quality. In addition, the Perficiency factor, Outotec's rating for plant performance efficiency, is introduced. During the recent commissioning of a pyrite roaster, the concept of the Roaster Optimizer was successfully transferred from zinc roasting application to a pyrite roasting plant, including gold recovery. In addition, this paper describes how the existing optimization system was complemented with advanced features for the plant commissioning and start-up phase, as well as using a dynamic training simulator for plant operators.
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