AP19676107 — Development of technology for complex processing of industrial waste from vanadium production

Project goal: development of a rational technology for processing industrial products of vanadium production with the extraction of vanadium, molybdenum, nickel and production of technical sodium hydroaluminate and scientific and theoretical substantiation of the processes of thermal decomposition, leaching, sorption and concentration of vanadium, molybdenum, nickel and precipitation of technical sodium hydroaluminate .

Relevance: Currently, there is a growing interest in rare refractory metals (molybdenum and vanadium), as well as in nickel, due to increasing demand from enterprises in various industries. This demand, in turn, requires the search for new sources of raw materials. One of them may be industrial products from metallurgical industries. Based on the obtained physicochemical results of studying the initial samples of technogenic waste, a method for leaching vanadium and molybdenum without thermal decomposition will be developed. During the research, a method for the thermal decomposition of industrial waste by the method of sulfatization and conversion of valuable components into an easily soluble form will be scientifically substantiated, optimal conditions for alkaline sintering will be developed to convert aluminum oxide from α- to sodium aluminate, and a technology will be developed to obtain concentrates of rare and non-ferrous metals.

Scientific adviser: PhD , Assoc .  Professor, Yulusov Sultan

Results obtained: Within the project, comprehensive physicochemical studies of technogenic waste from vanadium production were carried out to determine its phase and chemical composition. Optimized acid and alkaline leaching methods, as well as a combined pyro-hydrometallurgical processing scheme, were developed to ensure efficient recovery of vanadium, molybdenum, aluminum, and nickel. Key process parameters were established, including the use of oxidizing agents and sorption techniques for concentration and purification of target components. High-grade commercial products were obtained, and the technological feasibility of the proposed scheme was confirmed at the pilot laboratory scale. A novel processing method for technogenic raw materials was developed, patented, and supported by a closed-loop process flow scheme. The results demonstrate high efficiency, environmental safety, and strong potential for industrial implementation.

List of publications with links to them

1. Yulusov, S., Sarsembayeva, M., Surkova, T., Yerik, M., Dronenko, A. On the question of extracting valuable components from spent catalyst // Canadian Metallurgical Quarterly. – 2025. – P. 1–11. – DOI: https://doi.org/10.1080/00084433.2025.2523645
2. Yulusov, S.B., Sarsembayeva, M.R., Khabiyev, A.T., Retnawati, H., Merkibayev, Y.S., Akbarov, M.S., Baltabay, T.Y. Innovative approaches to the processing of vanadium- and molybdenum-containing technogenic waste // Complex Use of Mineral Resources. – 2025. – DOI: https://doi.org/10.31643/2027/6445.10
3. Yulusov, S., Baigenzhenov, O., Khabiyev, A., Torsykbayeva, B., Merkibayev, Y. Vanadium-Containing Sources and Processing Technologies: A Comprehensive Review // Journal of Applied Science and Engineering. – 2025. – Vol. 28, No. 5. – P. 1161–1172. – DOI: http://dx.doi.org/10.6180/jase.202505_28(5).0020
4. Yulusov, S., Khabiyev, A., Merkibayev, Y., Akbarov, M., Konyratbekova, S. Investigation of the extraction of vanadium and molybdenum from vanadium production waste by alkaline leaching with sodium hypochlorite // Egyptian Journal of Chemistry. – 2025. – Vol. 68, SI: Z.M. Nofal. – P. 651–662. – DOI: https://doi.org/10.21608/EJCHEM.2025.405483.12067
5. Юлусов, С.Б., Байгенженов, О.С., Хабиев, А.Т., Меркибаев, Е.С. Обзор методов переработки техногенного ванадийсодержащего сырья // Вестник ВКТУ. – 2024. – № 2. – С. 105–113. – DOI: https://doi.org/10.51885/1561-4212_2024_2_105
6. Патент № 10349 Республика Казахстан. Способ извлечения ванадия из техногенного сырья / С.Б. Юлусов, А.А. Кузнецов, Н.К. Любимова, Е.Н. Жолдыбаев, А.Т. Хабиев, Е.С. Меркибаев. – Опубл. 14.10.2024, Бюл. № 22.