Scientific and Technical Program BR19777171 (2023–2025)
The scientists of the National Center “NC KPMS RK” are implementing the scientific and technical program BR19777171 “Development of fundamentally new technologies for the complex processing of polymetallic raw materials” for 2023–2025, funded under the program-target financing of the Industry Committee of the Ministry of Industry and Construction of the Republic of Kazakhstan.
The aim of the program is to develop and conduct pilot-industrial tests of technologies for the complex processing of hard-to-enrich high-silica polymetallic ores, obtaining new types of silicon-based alloys and composite lead- and zinc-containing materials. Development of technological regulations, technical specifications and process requirements for new innovative production facilities.
The main idea is the integrated processing of oxide and sulfide ores without beneficiation, using an ore-thermal furnace, separating silicon into the melt and lead and zinc into fumes. The new approach enables transferring 99% of lead and zinc into the gas phase and 70–80% of silicon into the melt. Traditional processing results in 90–95% silica-containing tailings and only 5–7% extraction of lead and zinc into concentrates.
The developed technology allows:
- to preserve and increase metal production;
- to obtain ferrous alloys (ferrosilicon, ferrosilicoaluminum, alumosilicomanganese, etc.);
- to extract zinc and lead from fumes and produce high-purity zinc, magnesium salts, and tribasic lead sulfate;
- to create corrosion-resistant electrochemical zinc coatings;
- to process off-grade ores and high-ash coals, reducing waste and emissions.
The technologies have completed a full cycle — from thermodynamic modeling and lab studies to pilot-industrial testing.
Experimental batches of ferroalloys were produced:
- calcium- and magnesium-containing alloy: 40–45% Si, 18–20% Al, 8–15% Ca, 2–4% Mg;
- alumosilicomanganese: Mn 28.60%, Si 41.40%, Al 14.05%, C 0.067%;
- ferrosilicon grades FS25, FS45, FS65;
- boron-containing low-aluminum ferrosilicon (Al removal 94.3–97.3%).
Products obtained from lead-zinc fumes:
- cathode zinc of grade CVO;
- MgCl2·6H2O, MgSO4·7H2O;
- 3PbO·PbSO4·2H2O (Pb 83.5%);
- corrosion-resistant electrochemical zinc coatings.
The novelty is confirmed by obtaining 9 patents of the Republic of Kazakhstan (№8896, №8876, №9968, №8875, №36683, №10018, №10056, №10768, №10298). 22 scientific papers have been published (7 in journals with a CiteScore percentile in the Scopus database of at least 50); 5 in the KOKSNVO of the Ministry of Foreign Affairs of the Republic of Kazakhstan, abstracts in international conferences-10).
