Abstract:This paper studies a process system combining rotating cup granulation technology, particle flow heat transfer and exchange technology and gas-based direct reduction technology. The purpose of this system is to improve copper slag treatment efficiency and waste heat utilization rate. Material flow and energy flow of the process system are established. The system makes use of the advantages of particle flow, for instance high areal density and flowability in heat exchange and chemical reaction process. In the process system, liquid copper slag with high temperature is granulated into slag particles in dry granulation techniques, and the heat and valuable metals are recovered in particle flow heat transfer and gas-based direct reduction process modules which followed, respectively. Under the working condition designed in this paper, the copper slag can be treated continuously and instantly, which could reduce energy consumption and environmental cost of copper smelting process. It has the advantages of less space and no water consumption, compared with the slow-cooling process. The results of this study indicate that 431 kg sponge iron will be recovered for every ton of copper slag, in the meantime 77.5% of the total heat in slag will be recycling which can be reused for power generation 95 kWh.