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Pyroprocessing

Pyroprocessing equipment that improves efficiency and cuts CO₂

FLS's pyroprocessing innovation is increasing the energy efficiency of traditional systems while advancing alternative fuels and operating modes, such as hydrogen, electricity, and oxyfuel. These advancements enable miners to reduce the carbon footprint and improve the economics of critical mineral production.

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 When mining feels the heat

Certain ores require pyroprocessing at high temperatures to liberate the valuable material and unlock its economic value. For example, sulphide ores bearing zinc, copper, and lead must be roasted at temperatures between 500°C and 1000°C to release the metal. Calcining bauxite during alumina production requires temperatures up to 1100°C, while in smelting and refining, the temperature can reach over 1200°C. Generating these temperatures is an energy-intensive business with a significant carbon footprint.

In a world of rising critical mineral demand and sensitivity to greenhouse gas emissions, this places pressure on pyroprocessing systems to deliver the output needed more efficiently and with lower emissions by reducing consumption of fossil fuels (and, where possible, replacing them with clean alternatives). Building on pyroprocessing experience spanning more than 140 years - with over 1000 rotary kiln systems supplied - FLS is at the forefront of these efforts.

The latest pyroprocessing innovations

In our continued effort to reduce pyroprocessing emissions, FLS has developed the indirectly heated rotary kiln. Using electric resistance heating, this kiln achieves shell temperatures up to 750°C in processes not suitable for direct firing. Because there is no combustion, there are no combustion-based emissions, while other process-related emissions are minimised and easily mitigated.

For processes requiring direct firing in the kiln, we offer solutions for the partial or complete substitution of fossil fuels with lower-carbon alternative fuels, such as hydrogen, biogas/biomass, and fuel gas. We also support alternative operating modes, such as oxyfuel, that support efficiency and carbon capture solutions.

Recovering process heat significantly improves pyroprocessing efficiency, yet it is not always an easy ask. For applications where direct heat recovery is not possible, such as spodumene processing, the FLS indirect rotary cooler provides a solution. Incorporating indirect air cooling in addition to traditional water cooling, it recovers up to 50% of the sensible heat to lower specific fuel consumption in the kiln by more than 25%. It also reduces water consumption and plant footprint compared to water-only alternatives while delivering a final product temperature of about 100°C at a comparable cost.

Video

Innovation in action: the lithium Pyro Island

Featuring the indirect rotary cooler, the FLS Pyro Island aims to deliver maximum efficiency in spodumene conversion, a key part of lithium production.

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Frequently asked questions

We can typically substitute natural gas with up to 30% hydrogen without substantive changes to the equipment. Depending on the specific application and process conditions, higher substitution rates up to 100% may also be possible. To learn more about utilising hydrogen in your pyroprocess, contact our expert pyroprocessing team.

Yes! Electric heating is available for certain applications utilising indirect rotary kilns and for some drying applications. To learn more about our electric heating options, contact our expert pyroprocessing team.

Yes, FLS has multiple technologies to recuperate waste energy and utilise it for drying, preheating material, preheating combustion air, and other applications depending on the process and available waste energy.