BR23991563 “Creation of innovative resource-saving technologies for mining and integrated processing of mineral and technogenic raw materials”

The scientists of the National Center of RSE “NC CPMRM RK” are implementing the scientific and technical program BR23991563 “Creation of innovative resource-saving technologies for mining and integrated processing of mineral and technogenic raw materials” for 2024–2026, within the framework of program-targeted funding by the Committee of Industry of the Ministry of Industry and Construction of the Republic of Kazakhstan.

Objective: to develop technologies for the extraction of minerals under complex mining and geological conditions, to create technologies for the integrated processing of non-standard mineral and technogenic raw materials to obtain critically important metals, and to develop effective methods for CO₂ concentration and conversion to achieve a “zero” greenhouse gas emission balance.

Scientific results achieved include:

• Developed the Concept of an Automated Monitoring System and the Methodology for Integrated Assessment of In-Pit Haul Road Operation Efficiency;
• Developed safe and efficient methods for the reworking of abandoned pillars at the Zhezkazgan deposit;
• Developed the technical design of an automated system for monitoring and controlling the ventilation regime of underground mining workings;
• Developed the structure of a geodatabase and an algorithm for predicting hazardous deformation processes at deposits;
• For the first time, tested the developed probabilistic grinding model under laboratory, semi-industrial, and industrial mill conditions;
• Studied the content of associated components in flotation concentrate samples from polymetallic, copper, and molybdenum ores to determine the possibility of extracting PM and REM (Ba, Bi, Be, Co, Ge, Se, In, Te, etc.).

In scaled-up laboratory conditions, the following valuable products (KIM) were obtained from non-standard raw materials, metallurgical waste, and TMF:

• Copper product with 6.74% Cu content and 46.09% recovery from tailings;
• Barite concentrate of grade KB-1 with 95.47% BaSO₄ from gravity separation waste;
• Trivalent and tetravalent titanium chlorides from titanium scrap;
• Commercial products: nickel oxide, magnesium sulfate, iron oxide (α-Fe₂O₃) from magnesian nickel ores;
• REM-containing ferroalloy with composition (mass %): Si – 65–67; Al – ≈15; Y – 0.06–0.08; Fe – remainder from Kundaybay ore;
• Manganese concentrate with 26% Mn from residual tailings of manganese ore processing;
• Synthesized new refractory materials;
• Coal concentrate with 90% combustible matter recovery from coal enrichment waste;
• Developed and tested a new diaphragm electrolyzer design for the production of electrolytic high-purity manganese;
• Developed a mechanism for the directed conversion of refractory oxidized copper minerals into easily floatable sulfides;
• Determined the heat capacity and thermodynamic functions of cuprato-vanadato-manganites doped with La, Li, Ca, Na, K, Mg, Sr, Ba, s-element oxides, and YBa₂Cu₃Oₓ superconductor;
• Determined the optimal low-temperature roasting conditions (1200 °C, 60 min) of titanomagnetite concentrate with reducers; after wet magnetic separation of the residue, titanium dioxide concentration in the non-magnetic product reached 62.64% and iron 8.4%, with a titanium dioxide recovery of 88.2%;
• Developed technology for integrated processing of vapors at LLP “Balkhashpolymetal,” ensuring almost complete removal of arsenic as a compact arsenate-arsenite cake and obtaining commercial copper concentrates.

CO₂ utilization technologies were developed:

• From lead production waste, carbon-free technology regimes were developed to obtain metallic antimony (92% Sb) and sodium carbonate. CO₂ conversion to sodium carbonate reached 87%, and coke consumption for metal smelting was reduced by 16–20%;
• Developed a technology for industrial gas purification from carbon dioxide and determined the efficiency of a new CO₂ compound as a chemosorbent;
• Developed a method and technological scheme for producing a selective Ru–Rh/13X catalyst (1 mass %, Ru:Rh = 1:1) with immobilized glucose-6-phosphate. Developed the apparatus chain scheme for catalytic hydrogenation of carbon oxides in the presence of hydrogen and water vapor to produce hydrocarbons;
• Obtained optimal technological and temperature regimes for coal fuel combustion.

Tests on the production of ferroalloys and alloys containing KIM were conducted in small- and medium-capacity furnaces:

• Chromium-nickel ferroalloy was smelted using boron-containing ferrosilicochrome;
• Tungsten- and molybdenum-containing alloys were obtained;
• In experimental-industrial conditions, in a 630 kVA ore-thermal furnace, manganese- and chromium-containing alloys were smelted from non-standard raw materials, including poor and difficult-to-enrich ores;
• Casting of steel grinding balls using manganese- and chromium-containing alloys was performed in a KGPS-400KW/0.5T induction furnace with a 0.5 t capacity. The obtained blanks confirmed the technological feasibility of using new manganese- and chromium-containing alloys for grinding media production.

The novelty of technical solutions is confirmed by:

• Five certificates of registration in the State Register of Rights to Copyright-Protected Objects;
• Six patents for inventions and utility models of the Republic of Kazakhstan;
• Eight applications filed for inventions and utility models of the Republic of Kazakhstan:

1. Galiev S.Zh., Uteshov E.T., Galiev D.A., Tekenova A.T., Aksanaliev N.E., Sarsenbaev E.E.Certificate of registration in the State Register of Rights to Copyright-Protected Objects for the software Automated System for Monitoring the Efficiency of In-Pit Haul Roads – ASM-EVAD. No. 61673, August 26, 2025.
2. Makasheva A.M., Malyshev V.P.Certificate for the composite work “Adaptation of Probabilistic Theory to the Operating Conditions of Semi-Industrial-Scale Mills”. No. 59034, June 2, 2025.
3. Bimurat Zh., Baltieva A.A., Makhmetova G.N., Shamganova L.S. Certificate for software GeoMonitor.Al, a web application for visualization and analysis of geodynamic monitoring data. No. 60150, June 24, 2025.
4. Bimurat Zh., Baltiyeva A., Makhmetova G., Shamganova L.S. Copyright Certificate “GeoMonitor.Ai” // No. 66800 dated 28.01.2026 (database)
5. Bimurat Zh., Baltiyeva A., Makhmetova G., Shamganova L.S. Copyright Certificate “Web-Based System for Areal Geomonitoring and Geospatial Data Analysis ‘GeoMonitor.Ai’” // No. 66802 dated 28.01.2026 (computer programs / software)
6. Utility Model Patent RK No. 11113 “Method for Mining High (Over 6 m) Pillars in Gently Inclined Panels Using the Room-and-Pillar Mining System”. Volkov A.P., Egemberdiev R.A., Shabelnikov E.A., Volkov Yu.A., Noborokova N.N. Published September 12, 2025.
7. Utility Model Patent RK No. 10769 “Method for Leaching Nickel from Oxidized Nickel Ores”. Shayakhmetova R.A., Osipov P.A., Mukhametzhanova A.A., Kali A.A., Kuandykova A.N. Published June 20, 2025.
8. Utility Model Patent RK No. 10689 “Method for Manganese Extraction”. Mukhtar A.A., Makashev A.S., Kassymova B.K., Atakhan M.M., Makashov E.S. Reg. No. 2025/0539.2, published June 5, 2025.
9. Utility Model Patent RK No. 10288 “Method for Producing Double Cuprato-Vanato-Manganites of Lanthanum and Alkali Metals”. Kassenov B.K., Kassenova Sh.B., Sagintaeva Zh.I., Kuanyshbekov E.E., Turtubaeva M.O. Published March 14, 2025.
10. Patent for Invention No. 37349 “Method for the Reduction of Hexavalent Uranium.” Bayeshov A., Turlybekova M.N., Bayeshova A.K., Altynbek A.D. Published on 28.11.2025.
11. Patent for Invention No. 37853 “Method for Capturing and Utilizing Carbon Dioxide.” Zhumashev K.Zh., Narembekova A., Zharmenov A.A., Lu N.Yu., Terlikbayeva A.Zh., Berdikulova F.A. // Reg. No. 2024/0950.1, published on 27.02.2026.

2025–2026 Published Scientific Works:

1. Seitgali Galiyev, Daniyar Galiyev, Yerzhan Uteshov, Yevgeniy Shabelbnikov, Vladimir Makhonin, Aizhana Maldynova, Aizhan Tekenova, Nurlan Axanaliyev. “Enhancing Energy and Operational Efficiency of Geotechnological Complexes Using Geoinformation Technologies” // Emerging Science Journal. – No. 3 (2025). – 90th percentile. – P. 1372–1387. http://dx.doi.org/10.28991/ESJ-2025-09-03-013
2. Bimurat Zh., Makhmetova G.N. How to Design a Database for Effective GNSS Monitoring: A Step-by-Step Approach // Proceedings of the II International Scientific and Practical Conference of Young Scientists “Innotech Connect: Connecting Ideas and Technologies”. – Almaty, March 27–28, 2025. – P. 57–61.
3. Makasheva A.M., Malyshev V.P., Bekbayeva L.A. Modification of the Activation Factor in the Probabilistic Grinding Model Using Isomorphism // Science and Technology of Kazakhstan (Toraighyrov University, CQASHE). – 2025. – No. 2. – P. 312–328. https://doi.org/10.48081/RPJJ5492
4. Akberdin A.A., Kim A.S., Orlov A.S., Sultangaziev R.B. Mathematical Model of the Phase Composition Diagram of the Ni-B-Si System // Science and Technology of Kazakhstan. – 2025. – No. 3. – P. 217–227. https://doi.org/10.48081/VJZF6109
5. Mukhtar A.A., Makashev A.S., Kassymova B.K., Kochegina E.V., Atakhan M.M. Study of the Possibility of Magnetic Beneficiation of Technogenic Manganese Tailings // Science and Technology of Kazakhstan. – No. 4. – 2025. https://doi.org/10.48081/GDOV2218
6. Saulebek Zh.K., Abdirashit A.M., Toleukadyr R.T., Lu N.Yu. Studies of the Processes of Producing Molybdenum- and Tungsten-Containing Refractory Master Alloys Using Ferroalumosilicocalcium // Mining Journal of Kazakhstan. – 2025. – No. 9. – P. 63–69. https://doi.org/10.48498/minmag.2025.245.9.005
7. Kasenov B.K., Aldabergenov M.K., Bekturganov Zh.S., Yermagambet B.T., Kasenova Sh.B., Sagintayeva Zh.I., Balakayeva G.T., Isabayeva M.A., Kuanyshbekov E.E. Applied Thermodynamics in Chemistry and Metallurgy // Monograph. Publishing House of E.A. Buketov Karaganda University, 2025. – 476 p.
8. Kasenova Sh.B., Sagintayeva Zh.I., Kasenov B.K., Kuanyshbekov E.E., Temirbayeva E.M., Dyusembayev R.T. Synthesis, X-ray Diffraction, and Thermodynamics of Cuprato-Vanadato-Manganite LaNa2CuVMnO7.5 // Proceedings of the International Scientific and Practical Conference “XVII Saginov Readings. Integration of Education, Science and Production”, Karaganda, June 26–27, 2025. – P. 691–693.
9. Kasenov B.K., Kasenova Sh.B., Sagintayeva Zh.I., Kuanyshbekov E.E., Isabayeva M.A. Synthesis, X-ray Diffraction, and Thermodynamics of Cuprato-Vanadato-Manganite LaLi2CuVMnO7.5 // Bulletin of Shakarim University. Technical Sciences. – No. 3 (19). – 2025. – P. 593–601. https://doi.org/10.53360/2788-7995-2025-3(19)-66
10. Narembekova A.K., Zhumashev K.Zh., Zhinova E.V., Aitbayev N.B., Utegen Zh.D. Hydrometallurgical Processing of Arsenic-Containing Polymetallic Sublimates from Copper Smelting Production // Proceedings of the University. – 2025. – No. 3 (CQASHE). – P. 51–56. https://doi.org/10.52209/1609-1825_2025_3_51
11. Narembekova A.K., Zhumashev K.Zh. Arsenic Precipitation from Industrial Solutions of Non-Ferrous Metallurgical Enterprises // Proceedings of the International Scientific and Practical Conference “XVII Saginov Readings. Integration of Education, Science and Production”. – Karaganda, KarTU, 2025. – Part 3. – P. 60–61.
12. Efremova S.V., Satbayev B.N., Koketayev A.I., Shalabayev N.T., Satbayev A.B., Ryskaliyeva Zh.N., Ilyasova G.Kh. Experience of Scientific and Technical Cooperation in the Production and Marketing of Refractory Materials // XXII International Conference of Refractory Specialists and Metallurgists // NUST MISIS, May 22–23, 2025, Moscow. – New Refractories. – No. 3. – 2025. – P. 9–10.
13. Narembekova A.K., Zhumashev K.Zh., et al. Explorations in the Development of New Methods for Carbon Dioxide Capture and Utilization // Scientific Journal of Toraighyrov University. Science and Technology of Kazakhstan. – No. 2 (2025). – P. 267–273. https://doi.org/10.48081/VJZF6109
14. Baisanov A., Baisanov S., Amenov A., Vorobkalo N., Ibrakhimova Zh. Study on the Possibility of Smelting Manganese Ligature from Ferromanganese Ore Beneficiation Tailings // Proceedings of the University. – 2025. – No. 4 (CQASHE). – P. 32–38. https://doi.org/10.52209/1609-1825_2025_4_32
15. Kasenov B.K., Aldabergenov M.K., Bekturganov Zh.S., Yermagambet B.T., Kasenova Sh.B., Sagintayeva Zh.I., Balakayeva G.T., Isabayeva M.A., Kuanyshbekov E.E. Applied Thermodynamics in Chemistry and Metallurgy // Monograph. Publishing House of E.A. Buketov Karaganda University, 2025. – 476 p.
16. Boyandinova A.A., Adilkhanova Zh.A. An Approach to Project Management Decisions for Open-Pit Geotechnological Complexes with Motor Transport // Mining Journal of Kazakhstan. – Almaty, 2025. – No. 12 (248). – P. 11–16.
17. Myrzabekov B.E., Makhanbetov A.B., Gaipov T.E., Abzhalov B.S., Nurgaliyev N.N. Electrochemical Reduction of Manganese (II) Ions on Titanium and Lead Electrodes // Academic Journal of Physical and Chemical Sciences. – 2025. – No. 4. – P. 286–297. https://doi.org/10.32014/2025.2518-1483.400
18. Zh. Bimurat, B. Zh. Sagindykov, G. N. Makhmetova, A. A. Baltiyeva. Modeling and Analysis of Earth’s Surface Deformations via InSAR // Eurasian Mining. – 2025. – No. 2. – P. 37–42. DOI: 10.17580/em.2025.02.07
19. A.S. Orlov, A.A. Akberdin, A.S. Kim, R.B. Sultangaziev. Mathematical Models of Phase Composition Diagrams in Multicomponent Oxide Systems and Their Applied Significance // CIS Iron and Steel Review. – 2025. – No. 30. – P. 46–51. https://doi.org/10.17580/cisisr.2025.02.08
20. F. Berdikulova, N. Seidakhmetova, E. Mazulevsky, T. Kovzalenko, B. Ondiris. Features of Antimonate Concentrate Reduction in Alkaline Melts Under Carbon-Neutral Smelting Conditions // Metals. – 2026. – Vol. 16. – Article 265. https://doi.org/10.3390/met16030265
21. Boyandinova A.A., Adilkhanova Zh.A. Key Indicators of Project Management Decisions for the Sustainable Functioning of Geotechnological Complexes // Mining Informational and Analytical Bulletin. – 2026. – No. 2-1. – P. 182–196. DOI: 10.25018/0236_1493_2026_21_0_182