Zhubanov Aktobe Regional University, Aktobe, Kazakhstan

A. A. Turgaliev, Postgraduate, Dept. of Metallurgy and Mining, Faculty of Engineering
O. R. Sariev, Cand. Eng., Associate Prof., Prof. of the Dept. of Metallurgy and Mining, Faculty of Engineering, e-mail: rafhatsson@mail.ru

Aktobe Ferroalloys Plant, Branch of JSC TNK Kazchrome, Aktobe, Kazakhstan
E. E. Abdulabekov, Director
R. S. Kazbekov, Production Director
A. O. Kuandykov, Process Management Coordinator, Slag Processing Shop

This paper examines a solution to the resolving problem of recycling depleted chrome tailings – a large-scale waste product using the example of waste heaps of the Donskoy Mining and Processing Plant (DMPP), which have accumulated approximately 3 million tons of raw materials containing 15–25 % Cr₂O₃. This demonstrates not only the environmental benefits but also the significant raw material feasibility of processing it in the context of depleted high-grade ore reserves. Jigging was selected as the primary beneficiation method using KPFSh-50 systems in the slag processing shop of the Aktobe Ferroalloys Plant (AktFP). To improve its efficiency, a comprehensive optimization of the key process parameters was implemented, including increasing the pulsation frequency to 2–2.5 lifts per second to intensify bed loosening, replacing standard screens with 3 mm wide slotted screens to prevent clogging by fine particles and ensure a stable airflow, and increasing the water supply to reduce the viscosity of the medium and facilitate particle separation. Pilot tests conducted at AktFP and Aksu Ferroalloys Plant (AksFP) confirmed the high technological efficiency of the proposed circuit: for the 5-10 mm tailings fraction, the extraction of 73.1 % Cr₂O₃ was achieved at Aksu Ferroalloys Plant, and for the 0-10 mm fraction, it is 66.6 % Cr₂O₃. The resulting concentrate, with a content of 32-51 % Cr₂O₃, fully complies with the requirements for smelting shop charge materials, and the reproducibility of the technology was proven at Aksu Ferroalloys Plant, where the extraction was 66.7 %. The economic effect of implementing the technology, estimated at USD 15 million for Aksu Ferroalloys Plant and USD 6 million for Aksu Ferroalloys Plant, is achieved through the creation of a stable source of secondary raw materials, a reduction in the cost of purchasing primary concentrate, and a decrease in environmental payments. Thus, the successful implementation of circular economy principles has been demonstrated, allowing industrial waste to be reclassified from an environmental hazard to a strategic raw material reserve for the ferroalloy industry.

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