AR19680477 – Development of a comprehensive technology for processing nickel-cobalt-containing ores using pyro- and hydrometallurgical processes

The goal of the Project is to develop a comprehensive technology for processing low-grade nickel-cobalt-containing ores and concentrates using pyro- and hydrometallurgical processes, including oxidative - sulfatizing roasting of source materials with further hydrometallurgical processing of the cinder and extraction of target non-ferrous metals (iron, nickel and cobalt) in the form of powders of these metals

Relevance: The raw materials for nickel and cobalt are sulfide and laterite ores. In Kazakhstan, nickel and cobalt are mainly found in laterite ores, but the latter, due to the complexity of their processing, are still not involved in production. An additional source of these metals is the tailings of existing enterprises. Today, magnetic separation tailings, which contain a number of valuable components (cobalt, nickel, copper, precious metals, etc.), are not processed, but are stored in tailings ponds occupying large areas of agricultural land. In addition, a significant amount of them is lost in tailings and technogenic raw materials produced by the country’s existing metallurgical enterprises, for example , more than 7 thousand tons are lost in the Sokolovsko-Sarbaisky mining and processing plant alone. nickel and 14 thousand tons of cobalt per year. As research results have shown, today there is no universal processing method for nickel-cobalt-containing ores and production wastes. At the same time, the pyrite -cobalt concentrates obtained at the Sokolovsko-Sarbaisky mining and processing plant , due to the complexity of their composition, do not allow the use of standard technologies for their complex processing. This problem necessitates research and development of an effective combined technology for the extraction of iron, nickel and cobalt from raw ores and tailings containing valuable metals.

Scientific supervisor: PhD , associate professor, Mamyrbaeva Kulzira Kaldybekovna

Results obtained: Within the project, an efficient combined technology for processing nickel–cobalt-bearing ores and technogenic materials was developed. The integration of pyro- and hydrometallurgical processes demonstrated high extraction efficiencies for nickel and cobalt (up to and above 90%). Optimal parameters for key stages, including sulfation roasting, acid and autoclave leaching, as well as extraction and precipitation processes, were determined. Based on the obtained results, a comprehensive technological scheme was designed and validated through pilot-scale laboratory tests. The proposed technology is characterized by environmental safety, economic feasibility, and the ability for complex utilization of raw materials. The results are recommended for industrial implementation and application in educational programs.

List of publications with links to them

1. Mamyrbayeva K. K., Kuandykova A. N., Chepushtanova T. A., Merkibayev Y. S. Study of the Conditions for the Selective Extraction of Metals (Iron, Copper, Cobalt and Nickel) from Pyrite Cinder Leaching Solutions // IITER International Conference. – Rome, Italy, 2023. – P. 47–51.
2. Mamyrbayeva K. K., Kuandykova A. N., Chepushtanova T. A., Merkibayev Y. S. Review of technology for hydrometallurgical processing of lateritic nickel ores over the past 20 years in the world // Non-Ferrous Metals. – 2024. – P. 13–21. – URL: https://rudmet.net/media/articles/Article_NFM_01_24_pp.13-21.pdf
3. Мамырбаева К. К., Куандыкова А. Н., Чепуштанова Т. А., Меркибаев Е. С., Бражендра М. Исследование извлечения никеля и кобальта из хвостов магнитного обогащения // Engineering Journal of Satbayev University. – 2024. – Т. 146, № 5. – С. 1–9. – URL: https://vestnik.satbayev.university/index.php/journal/article/view/1339/660
4. Mamyrbayeva K. K., Kuandykova A. N., Chepushtanova T. A. Thermodynamic analysis of sulfatizing roasting of stale nickel-cobalt-containing wastes from operating plants // 24th International Multidisciplinary Scientific GeoConference SGEM. – 2024. – Vol. 4, No. 2. – P. 151–158. – URL: https://epslibrary.at/sgem_jresearch_publication_view.php?page=view&editid1=10113
5. Мамырбаева К. К., Чепуштанова Т. А., Куандыкова А. Н., Меркибаев Е. С. Способ извлечения никеля и кобальта из хвостов и пиритных концентратов: патент. – 2025.
6. Мамырбаева К. К., Куандыкова А. Н., Меркибаев Е. С., Мишра Б. Исследование процесса сульфатизирующего обжига латеритной окисленной никелевой руды для разработки комбинированной технологии переработки // Горный журнал Казахстана. – 2025.
7. Mamyrbayeva K. K., Kuandykova A. N., Chepushtanova T. A., Merkibayev Y. S., Mishra B. Investigation of the sulfation-roasting–water leaching process for efficient recovery of nickel and cobalt from Kazakhstan’s laterite ore // Canadian Metallurgical Quarterly. – 2025. – (на стадии рецензирования). – URL: https://doi.org/10.1080/00084433.2025.2603070