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