For the reduction of energy and material resources consumption in base metals production, improvement of process efficiency, enhancement of flexibility to raw material resources and development of novel processes are required. One of our approaches for this issue is numerical process simulation to reproduce and evaluate the materials production processes, based on the theories of multiphase fluid dynamics, reaction kinetics, thermodynamics, thermal fluid engineering, transport phenomena, powder technology, and so on. Using the results of the process analysis and the fruits obtained through the modeling of unit operations, we are trying to develop novel material production technology. Additionally, we are trying to develop new processes for recovery and storage of thermal energy.