AP08052829 – Development of complex treatment hybrid technology of oxidized, resistant zinc, lead-bearing ores and beneficiation middlings by sulphidizing roasting with subsequent cinder enrichment

Relevance: In flotation enrichment of polymetallic ores, a significant amount of zinc and lead passes into tailings and industrial products, and to pyritic concentrates obtained during enrichment. In conditions when the ore base of non-ferrous metallurgy is exhausted, it becomes urgent to involve in processing tailings and industrial products of enrichment and to develop technologies for efficient processing of oxidized and mixed ores. When the project is implemented, pre-extraction of lead and zinc is solved; transfer of illiquid product to the balance product; ecological problem of accumulation of waste products through their processing, reduction of their quantities. Getting lead and zinc is a surplus trend today. The global lead deficit in May 2020 was 37.2 thousand tons, while the global zinc deficit was 360 thousand tons. Zinc consumption per capita is increasing by 1.8% per year.

Objective of the project: To substantiate and develop the technology of complex processing of oxidized and mixed polymetallic ores and industrial products by sulfidizing roasting with a pyrite concentrate followed by magnetic and flotation enrichment of the cinder providing increased recovery of zinc and lead from oxidized and mixed polymetallic ores and industrial products to selective concentrates. Establish a process mechanism and sulfidization conditions to produce magnetic pyrrhotite and hydrophobic sulphides of lead and zinc. Determine the conditions of magnetic and flotation enrichment. Prepare a task assignment for larger studies.

Scientific supervisor: PhD, Associate Professor, Chepushtanova Tatyana Aleksandrovna

Results obtained: Within the framework of the research work, a technology for the комплекс processing of oxidized and mixed polymetallic ores using sulfidizing roasting followed by beneficiation of the calcine was developed. Thermodynamic, kinetic, and physicochemical studies were carried out, which made it possible to determine optimal sulfidization conditions in the temperature range of 600–800 °C. The formation patterns of pyrrhotite with high magnetic susceptibility were identified, and optimal conditions for magnetic and flotation separation were substantiated. Pilot-scale tests confirmed the effectiveness of the technology, ensuring zinc recovery up to 90% and lead recovery up to 80%. A technological regulation and a feasibility study were developed, demonstrating high economic efficiency with a payback period of about 1.1 years. The proposed technology enables the вовлечение of technogenic waste into processing and reduces environmental impact. The results confirm a high scientific and technical level and strong competitiveness of the developed solution.

List of publications with links to them

1. Меркибаев Е.С., Луганов В.А., Чепуштанова Т.А., Гусейнова Г.Д., Мишра Б. Термодинамическое обоснование высокотемпературного сульфидирования оксида цинка // Вестник КазНИТУ. – 2020. – № 2. – URL: https://official.satbayev.university/download/document/14648/%D0%92%D0%95%D0%A1%D0%A2%D0%9D%D0%98%D0%9A-2020%20%E2%84%962.pdf
2. Chepushtanova T.A., Motovilov I.Y., Merkibayev Y.S., Sarsenova M.S., Sumedh G. Technology of sulfidizing-pyrrhotizing roasting of lead flotation tailings // Journal of Mining and Geological Science. – 2020. – Vol. 63. – P. 31–37. – URL: https://mgu.bg/wp-content/uploads/resources/Journal-of-MG-Sciences-63-2020.pdf
3. Чепуштанова Т.А., Меркибаев Е.С., Мотовилов И.Ю., Поляков К.В. Разработка гибридной технологии сульфидирующего обжига цинк-, свинецсодержащих промпродуктов обогащения // Горный журнал Казахстана. – 2021. – № 10. – С. 26–33. – URL: http://minmag.kz/ru/archive_dates/2021/?lang=ru_RU
4. Темiрхан С.Ғ., Чепуштанова Т.А. Технологические исследования пирротинизирующего обжига окисленной свинцово-цинковой руды и промпродукта обогащения ТОО «Казцинк» // Сатпаевские чтения – 2021: материалы междунар. науч.-практ. конф. – Алматы, 2021. – Т. 1. – С. 1027–1031. – URL: https://official.satbayev.university/ru/materialy-satpaevskikh-chteniy
5. Чепуштанова Т.А., Поляков К.В., Меркибаев Е.С. Технология переработки хвостов обогащения свинцово-цинковых руд методом активирующего сульфидирующего обжига // Инновация-2021: материалы XXV междунар. науч.-практ. конф. – Ташкент, 2021. – С. 70–72. – URL: https://www.kon-ferenc.ru/konferenc30_09_21.html
6. Чепуштанова Т.А., Меркибаев Е.С., Сарсенова М.С., Темiрхан С.Ғ. Комплексная переработка сложных полиметаллических руд месторождения Жайрем с использованием процесса сульфидирования // Байконуровские чтения – 2021: материалы междунар. конф. – 2021. – С. 317–322. – URL: https://zhezu.kz/index.php/ru/2019-09-23-11-55-05
7. Chepushtanova T.A., Merkibayev Y.S., Mishra B., Kuldeyev I.E. Processing of the zinc-lead-bearing flotation middlings by sulfidizing roasting with pyrrhotite production of predicted properties // Non-ferrous Metals. – 2022. – № 2. – https://rudmet.net/media/articles/Article_NFM_02_22_pp.15-24.pdf 
8. Chepushtanova T.A., Motovilov I.Y., Merkibayev Y.S., Polyakov K.V. Flotation studies of the middling product of lead-zinc ores with preliminary sulfidizing roasting of oxidized lead and zinc compounds // Kompleksnoe ispolzovanie mineralnogo syra. – 2022. – № 4. – P. 77–83. – DOI: 10.31643/2022/6445.43 – URL: https://kims-imio.kz/portfolio-item/%e2%84%9632022/
9. Меркибаев Е.С., Чепуштанова Т.А., Мотовилов И.Ю., Луганов В.А., Темiрхан С.Ғ. Термическое сульфидирование поверхности окисленных цинковых и свинцовых минералов пиритом в присутствии восстановителя в трубчатой печи // Сатпаевские чтения – 2022: материалы междунар. науч.-практ. конф. – Алматы, 2022. – Т. 3. – С. 144–146. – URL: https://official.satbayev.university/ru/materialy-satpaevskikh-chteniy
10. Чепуштанова Т.А., Меркибаев Е.С., Луганов В.А. Способ переработки окисленной свинцово-цинковой руды: патент на полезную модель № 2022/0331.1; заявл. 30.05.2022; положительное решение от 15.06.2022.
11. Чепуштанова Т.А., Меркибаев Е.С. Переработка окисленных, труднообогатимых цинк-, свинецсодержащих руд и промпродуктов обогащения: монография. – 2022. – 100 с.