Satbayev University, Almaty, Kazakhstan:

T. A. Chepushtanova, Candidate of Technical Sciences, PhD, Head of Department “Metallurgical Processes, Heat Engineering and Technology of Special Materials”, Associate Professor, Mining and Metallurgical Institute, e-mail: t.chepushtanova@satbayev.university
Y. S. Merkibayev^*, Master’s Degree, Head of Laboratories of “Metallurgical Processes, Heat Engineering and Technology of Special Materials”, Mining and Metallurgical Institute, e-mail: y.merkibayev@satbayev.university
O. S. Baigenzhenov, PhD, Associate Professor of “Metallurgical Processes, Heat Engineering and Technology of Special Materials”, Mining and Metallurgical Institute, e-mail: O.Baigenzhenov@satbayev.university

Worcester Polytechnic Institute, Worcester, USA:

B. Mishra, Professor and Director of MPI Mechanical and Materials Engineering, E-mail: bmishra@wpi.edu

*Correspondence author.

Zinc and lead are one of the most used metals in the world. The average annual growth rate of the zinc market is about 3.5%. Half of the zinc consumed in the world is used as electroplating, more than 30% is spent on the production of zinc alloys, including for the production of brass and bronze. At present, polymetallic ores are the main raw material for the production of lead and zinc. The production technology includes flotation enrichment of the initial ore raw material with subsequent pyrometallurgical or hydrometallurgical processing of the resulting concentrates. Unfortunately, the reserves of well-enriched sulfide ores are declining, which leads to the need to involve mixed and oxidized ores in the production. Obtaining zinc is also a relatively expensive process, one of the stages of which is the roasting of zinc sulfide concentrates in a fluidized bed furnace using oxygen-enriched air blast. In this regard, technologies aimed at processing hard-to-cut oxidized lead-zinc ores, as well as improving the process of roasting in a fluidized bed, are topical and in demand today. The article presents the technology and method for processing oxidized lead-zinc ore, including high-temperature sulfidizing roasting of oxidized compounds of lead and zinc, the results of roasting carried out in the presence of a high-sulfur sulfidizing agent in the form of pyrite (sulfur content is 45.15%), at molar ratios of metal oxide to pyrite NZnO/NFeS₂ and NPbO/NFeS₂ equal to 0.1–0.14 for sulfidizing in an air-blown fluidized bed furnace at a flow rate of 10 to 20 l/min, at a temperature of 750–800 °C, with a roasting time of 30–45 minutes. As a result of sulfidizing roasting, the degree of sulfidization reaches 88%, and the subsequent extraction of zinc from the non-magnetic fraction into a froth product in an open flotation cycle is 90% with a content of 23.4% zinc.
This study was funded by the Science Committee of the Ministry of Science and Higher Education of the Republic of Kazakhstan (grant no. AP15473200).

1. Chepushtanova T. A., Merkibayev Y. S., Mishra B., Kuldeyev Y. I. Processing of the Zinc-Lead-Bearing Flotation Mid dlings by Sulfidizing Roasting with Pyrrhotites Production by Predicted Properties. Non-ferrous Metals. 2022. Iss. 2. pp. 15–24.
2. Jinpeng Cai, Xiaodong Jia, Yinyu Ma, Ayman M. Ibrahim, Chao Su, Xingcai Yu, Peilun Shen, Dianwen Liu. Effect of pre-Oxidation on Copper-Lead Bulk Concentrate Flotation Separation with Sodium Polyacrylate as Galena Depressant. Separation and Purification Technology. 2023. Vol. 304. 122276.
3. Merkibaev Y., Panayotova M., Luganov V., Panayotov V., Chepushtanova T. Sulphidation Roasting as Means to Recover Zinc from Oxidised Ores. Comptes Rendus de L’Academie Bulgare des Sciences. 2018. Vol. 71, Iss. 8. pp. 1116–1123.
4. Kaya M., Kursunoglu S., Hussaini S., Gul E. Leaching of Turkish Oxidized Pb – Zn Flotation Tailings by Inorganic and Organic Acids. PbZn 2020: 9^th International Symposium on Lead and Zinc Processing. 2020. pp. 447–468.
5. Smith W. M., Brooks P. J., May R. A. Engineering Design for a Ferric Chloride Leaching Plant to Leach Complex Base Metal Sulphides. CIM Bulletin. 1997. Vol. 90. pp. 57–63.
6. Xie Shengyu, Wang Yu, Ma Chuan, Zhu Gefu, Wang Yin, Li Chunxing. Pyrolysis of Antibiotic Mycelial Residue for Biochar: Kinetic Deconvolution, Biochar Properties, and Heavy Metal Immobilization. Journal of Environmental Management. 2023. Vol. 328. 116956.
7. Zhang F.-Y., Zheng Y.-J., Peng G.-M. Deselenization and Detellurization of Precious-Metal Ore Concentrates by Swelling Oxidizing Roasting and Successive Alkaline Leaching. International Journal of Minerals, Metallurgy and Materials. 2017. Vol. 24, Iss. 2. pp. 147–155.

8. Lapin A. Y., Kositskaya T. Y., Shneerson Y. M., Bogdanov V. I. Production of Marketable Products by Processing Tin-Copper Ore Tailings. Tsvetnye Metally. 2020. No. 9. pp. 91–99.
9. Beysebaev B. B., Kenjaliev B. K., Gorkun V. I., Govndovskaya O. Yu., Ignatyev M. M. Deep Processing of Lead-Zinc and Intermediary Products with Receiving of Products with Increased Marketability. Almaty: Gylym, 2002. 219 p.
10. Chepushtanova T. A., Luganov V. A., Ermolayev V. N., Mishra B., Gyseinova G. D. Investigation of the Magnetic and Flotation Properties of Synthesized Hexagonal Pyrrhotites. Mineral Processing and Extractive Metallurgy Review. 2015. Vol. 36, Iss. 4. pp. 237–241.
11. Chepushtanova T. A., Mamyrbaeva K. K., Luganov V. A., Mishra B. Mechanism of Nonoxidizing and Oxidative Pyrrhotite Leaching. Minerals and Metallurgical Processing. 2012. Vol. 29, Iss. 3. pp. 159–164.
12. Sait Kursunoglu, Nilufer Kursunoglu, Shokrullah Hussaini, Muammer Kaya. Selection of an Appropriate Acid Type for the Recovery of Zinc from a Flotation Tailing by the Analytic Hierarchy Process. Journal of Cleaner Production. 2021. Vol. 283. 124659.
13. Luganov V. A., Chepushtanova T. A., Baiysbekov S. Sulfidization Roasting of Low Grade Lead-Zinc Oxide Ore with Pyrite. Proceedings – European Metallurgical Conference, EMC 2011. 2011. Vol. 2. pp. 441–454.
14. Shokrullah Hussaini, Sait Kursunoglu, Soner Top, Zela Tanlega Ichlas, Muammer Kaya. Testing of 17-Different Leaching Agents for the Recovery of Zinc from a Carbonate-Type Pb – Zn Ore Flotation Tailing. Minerals Engineering. 2021. Vol. 168. 106935.
15. Gulyashinov A. N., Antropova I. G., Kalinin Yu. O., Nikiforov K. A., Khanturgaeva G. I. Method of Processing Oxidized Lead Ore. Patent RU No. 2179596 C2. Published: 20.02.2002. Bul. No. 5 MPK C22B 13/00.
16. Wei Liu, Lin Zhu, Junwei Han, Fen Jiao, Wenqing Qin. Sulfidation Mechanism of ZnO Roasted with Pyrite. Scientific Reports. 2018. Vol. 8, Iss. 1. 9516.
17. Tianfu Zhang, Wei Liu, Junwei Han, Guiting Wu, Fen Jiao, Wenqing Qin. Selective Separation of Calcium from Zinc-Rich Neutralization Sludge by Sulfidation Roasting and HCl Leaching. Separation and Purification Technology. 2021. Vol. 259. 118064.
18. Yue Zhang, Xiaolin Zhang, Xinxin Liu, Tiancang Chang, Shuai Ning, Peilun Shen, Ruizeng Liu, Hao Lai, Dianwen Liu, Xinyu Yang. Carrageenan Xanthate as an Environmental-Friendly Depressant in the Flotation of Pb – Zn Sulfide and Its Underlying Mechanism. Colloids and Surfaces A: Physicochemical and Engineering Aspects. Vol. 653. 129926.
19. Jingshen Dong, Quanjun Liu, S. H. Subhonqulov, Jie Sheng, Yalong Gao, Meilin Liu. Research on the Flotation of Sphalerite and Germanium-Bearing Sphalerite Activated by Copper Ion and its Mechanism Difference. Minerals Engineering. 2022. Vol. 186. 107756.
20. Wang Jinming, Wang Yuhua, Yu Shilei, Yu Fushun. Study on Sulphidization Roasting and Flotation of Cervantite. Minerals Engineering. 2014. Vol. 61. pp. 92–96.
21. Qicheng Feng, Meili Wang, Ga Zhang, Wenjuan Zhao, Guang Han. Enhanced Adsorption of Sulfide and Xanthate on Smithsonite Surfaces by Lead Activation and Implications for Flotation Intensification. Separation and Purification Technology. 2023. Vol. 307. 122772.
22. Qian Zhang, Shuming Wen, Qicheng Feng, Han Wang. Enhanced Sulfidization of Azurite Surfaces by Ammonium Phosphate and Its Effect on Flotation. International Journal of Minerals, Metallurgy and Materials. 2022. Vol. 29, Iss. 6. pp. 1150–1160.
23. Kharitidi G. P., Rastyapin V. V., Volkova G. P., Dudin R. N., Oparina A. N. Possibility of Reducing Gaseous Emissions During the Treatment of Oxidized Nickel Ores. Tsvetnye Metally. 1984. No. 5. pp. 17–20.
24. Wenyuan Li, Zhiqiang Huang, Hongling Wang, Rukuan Liu, Liaoyuan Ouyang, Shuyi Shuai, Shiyong Zhang, Chen Cheng, Xinyang Yu, Guichun He, Weng Fu. Froth Flotation Separation of Phosphate Ore Using a Novel Hammer-Like Amidoxime Surfactant. Separation and Purification Technology. 2023. Vol. 307. 122817.
25. Shaojun Bai, Jie Li, Yunxiao Bi, Jiaqiao Yuan, Shuming Wen, Zhan Ding. Adsorption of Sodium Oleate at the Microfine Hematite/Aqueous Solution Interface and its Consequences for Flotation. International Journal of Mining Science and Technology. 2023. Vol. 33, Iss. 1. pp. 105–113.
26. Yuqing Huang, Wanzhong Yin, Rongdong Deng, Dingquan Xing, Feng Rao. Strengthening Sulfidation Flotation of Hemimorphite via Pretreatment with Pb²⁺. Minerals. 2019. Vol. 9, Iss. 8. 463.
27. Luganov V. A. Properties and Implementation of Products of Dissociative Roasting of Pyrite Concentrates. 26^th International Mineral Processing Congress, IMPC 2012: Innovative Processing for Sustainable Growth – Conference Proceedings. 2012. pp. 3047–3057.
28. Putilova I. N. Guide to Practical Exercises in Colloid Chemistry. 4^th ed., rev. and exp. Moscow: Gosudarstvennoye izdatelstvo “Vysshaya schola”, 1961. p. 156.
29. Sze A., Erickson D., Ren L., Li D. Zeta-Potential Measurement Using the Smoluchowski Equation and the Slope of the Current–Time Relationship in Electroosmotic Flow. Journal of Colloid and Interface Science. 2003. Vol. 261. pp. 402–410.
30. Werner C., Kоnig U., Augsburg A., Arnhold C., Kоrber H., Zimmermann R., Jacobash H. J. Electrokinetic Surface Characterization of Biomedical Polymers — a Survey. Colloids and Surfaces A: Physicochemical and Engineering Aspects. 1999. Vol. 159, Iss. 2-3. pp. 519–529.
31. McDonald J. C., Duffy D. C., Anderson J. R., Chiu D. T., Wu H., Schueller O. J. A., Whitesides G. M. Fabrication of Microfluidic Systems Inpoly(dimethylsiloxane). Electrophoresis. 2000. Vol. 21. pp. 27–40.
32. Chepushtanova T. A., Merkibaev E. S., Luganov V. A. Utility Model Patent, Application No. 2022/0331.1 dated May 30, 2022. Method for Processing Oxidized Lead-Zinc Ore (Positive Decision of the Expertise – 06.15.2022).
33. Mamyrbayeva K. K., Luganov V. A., Merkibayev Y. S., Yesken Z., Orazymbetova S. D. Extraction of Copper From Dumps and Wastes of Leaching by Hydrochloric Acid. WASTES – Solutions, Treatments and Opportunities II – Selected papers from the 4^th edition of the International Conference Wastes: Solutions, Treatments and Opportunities, 2017. 2018. pp. 339–344.