MINEX Forum

Tag: ferroalloys

  • Kazakh Scientists Develop Near Zero-Waste Technology for Processing Complex Polymetallic Ores

    Kazakh Scientists Develop Near Zero-Waste Technology for Processing Complex Polymetallic Ores

    Specialists from Kazakhstan’s National Center for Integrated Processing of Mineral Raw Materials have developed and successfully tested an advanced technology for processing complex polymetallic ores from the Shalkiya and Zhairem deposits.

    According to Kazakhstan’s Ministry of Industry and Construction, traditional mineral processing methods remain highly inefficient, with up to 90–95% of processed material ending up as waste while valuable components are lost. The newly developed technology is designed to maximize raw material utilization and significantly reduce tailings volumes.

    The key innovation lies in the carbothermic processing of lead-zinc ores with high silicon content using ore-thermal furnaces. Under conventional processing schemes, silica is discarded into tailings storage facilities. The new method instead converts silica into marketable ferroalloys, while lead and zinc transition into the gas phase for subsequent concentration and extraction.

    Pilot-industrial testing was conducted using furnaces with capacities ranging from 80 to 630 kVA. The process produced:

    • Ferrosilicon grades FS45, FS65 and FS75

    • Ferrosilicoaluminum

    • Aluminosilicomanganese

    • New calcium- and magnesium-containing ferroalloys

    Researchers also focused on processing lead-zinc sublimates. As a result, they obtained:

    • High-purity zinc (grade TsV0)

    • Magnesium compounds

    • Tribasic lead sulfate

    • Advanced composite electrochemical coatings with high corrosion resistance

    The developers describe the project’s main achievement as the creation of an almost waste-free processing scheme. Unlike conventional methods, where silicon is entirely lost in enrichment tailings, the new technology converts it into commercial products. More than 99% of lead and zinc are transferred into concentrated form.

    The research team has secured more than 10 patents covering the new solutions for difficult-to-process ores. Technical specifications have also been prepared for designing ferroalloy production facilities and complexes for processing sublimates. Preliminary calculations indicate that product value generated per unit of cost could more than double compared with existing processing technologies.

  • Kazakhstan Plans Launch of New Metallurgical Plants Under Multi-Year Industry Expansion

    Kazakhstan Plans Launch of New Metallurgical Plants Under Multi-Year Industry Expansion

    Kazakhstan is set to accelerate development of its metallurgical sector, with seven new metallurgical enterprises scheduled to begin operations in 2026, according to the Ministry of Industry.

    The total investment in the first phase of projects is estimated at KZT 154 billion. By the end of the year, the country expects to commission new production facilities manufacturing ferrosilicon, longitudinal welded and galvanised pipes, as well as reinforcing steel products of various diameters. The projects are expected to create more than 1,100 jobs across several regions.

    A further seven metallurgical plants are planned for launch within the following two years, supported by investments exceeding KZT 2 trillion. These facilities will focus on the production of ferroalloys, profile and strip steel, steel billets, large-diameter pipes and industrial wire products.

    The Ministry projects that expansion in the ferrous metallurgy sector will generate approximately 3,500 additional jobs between 2027 and 2028, including around 1,200 positions in rural areas.

    In parallel, another 16 industrial projects are currently at the design and approval stage. Planned developments include production of high-purity manganese, hot-briquetted and sponge iron, premium-grade steel, grinding balls and other materials required by Kazakhstan’s mining and metallurgical complex.

    Potential investment in these longer-term initiatives could reach KZT 2.8 trillion and is expected to create up to 5,500 additional jobs nationwide.

    Despite strong investment momentum, early-year production indicators in the sector showed mixed performance. Steel output declined by 5.7 percent to 339,500 tonnes, while rolled steel production increased by 11.1 percent to 292,400 tonnes, reflecting shifting demand dynamics within domestic and export markets.

  • Chevron Fund Invests $23.5m in Ferroalloy Production Project in Ekibastuz

    Chevron Fund Invests $23.5m in Ferroalloy Production Project in Ekibastuz

    Chevron Direct Investment Fund (CDIF) will invest $23.5 million in the construction of a ferroalloy plant in Ekibastuz, supporting Kazakhstan’s efforts to expand value-added metals production.

    The project is being developed by  (MPI), which plans to produce 80,000 tonnes of ferrosilicon-75 annually. The facility’s technology will also allow for the production of ferromanganese and silicomanganese. More than 500 jobs are expected to be created.

    According to MPI, South Korea’s SAC Co. will act as the project’s technology partner. The plant will be equipped with eight electric furnaces, each with a capacity of 33 MVA. Output is intended for export to South Korea, Japan, North America and European markets. The first production phase is scheduled to launch in 2026.

    Earlier, the  (DBK) announced it would allocate €148 million to finance the project. Total construction costs are estimated at €213 million, with MPI and Chevron contributing approximately €65 million in equity.

    Chevron has operated in Kazakhstan for more than three decades. Through CDIF, the company invests in promising domestic enterprises across various sectors to support economic diversification. The MPI project is expected to strengthen the industrial base of the Pavlodar region and expand Kazakhstan’s presence in global ferroalloy markets.

  • ERG to Invest Over $1 Billion in Mining and Metallurgical Projects in Kazakhstan

    ERG to Invest Over $1 Billion in Mining and Metallurgical Projects in Kazakhstan

    Eurasian Resources Group (ERG) plans to invest more than $1 billion in its mining and metallurgical assets in Kazakhstan, marking the largest investment programme in the country in the company’s history.

    The funding will be directed primarily toward ERG’s existing operations, as well as the construction of new production facilities and projects focused on higher value-added products. The investment plans were announced by ERG CEO Shukhrat Ibragimov during a visit to one of the group’s Kazakh sites this week.

    Kazakhstan remains ERG’s core operating base, accounting for more than one-third of the country’s total metals and mining output. The company is also a major player in the Democratic Republic of Congo, where its Metalkol operation ranks among the world’s largest cobalt producers and is a significant source of copper. The government of Kazakhstan holds a 40% equity stake in ERG.

    Key projects scheduled for development this year include a hot briquetted iron (HBI) plant with a planned capacity of 2 million tonnes per year, an iron ore pelletising facility, and an 80-megawatt ferroalloy gas utilisation power station at the Aktobe ferroalloys plant in northwestern Kazakhstan.

    Additional investments will support the development of a new chromium mine with annual capacity of 7.5 million tonnes, as well as modernisation of the Aksu power station. At the Pavlodar alumina plant, ERG plans to build vertical calcination kilns, install new product filtration units, and add recovery facilities capable of producing up to 15 tonnes of gallium per year.

    Both gallium and HBI, which are used in semiconductors, advanced alloys and steelmaking, are not currently produced in Kazakhstan, making these projects strategically significant for the country’s industrial diversification.

    Separately, ERG signed a three-year cobalt supply agreement in 2024 with Electra Battery Materials to supply its refinery in Ontario, Canada. From 2026, ERG is expected to deliver around 3,000 tonnes of cobalt hydroxide annually. Once fully commissioned, the refinery could produce enough cobalt to support battery production for up to 1.5 million electric vehicles per year.

  • Kazchrome Launches AI Integration Project at Aksu Ferroalloy Plant

    Kazchrome Launches AI Integration Project at Aksu Ferroalloy Plant

    The Aksu Ferroalloy Plant of JSC TNK Kazchrome, part of ERG, has begun implementing artificial intelligence (AI) tools into its IT-based furnace management system. The pilot initiative is being rolled out on ore-thermal furnace No. 64.

    The first phase of the project has been completed, including the collection, extraction, and analysis of three months of Big Data. Initial findings confirmed the strong potential of using this data to develop a recommendation-based AI model. In the future, the system is expected to help stabilise production processes, boost efficiency and energy savings, and reduce accidents and operating costs.

    “Today, introducing AI into the mining and metallurgical sector is no longer a trend but a matter of competitiveness and industrial safety,” said project manager Ruslan Eskendirov of ERG’s Research and Engineering Centre. “Our approach is pragmatic: sensors → data → models → measurable KPIs.”

    Earlier this year, ERG assembled a project team including specialists from its research and engineering centre, IT subsidiary BTS, Kazchrome, and the group’s metallurgy department. Working with an international technology partner that has already deployed similar AI tools at ferrochrome plants abroad, the team verified that the plant’s existing data is sufficient for building effective AI modules.

    Overall, ten AI modules are planned for deployment, each designed to optimise different aspects of furnace operation. One example is a predictive tool for electrode breakage, which could significantly reduce downtime and financial losses.

    The next phase will involve creating digital modules for controlling and monitoring furnace No. 64, integrating them into the existing automated process management system. The focus will be on predictive diagnostics, intelligent process optimisation, “soft sensors,” and operator guidance. If successful, the solution will be scaled across other furnaces.

  • Tokayev Meets Pavlodar Governor, Reviews Strong Economic Growth and Industrial Projects

    Tokayev Meets Pavlodar Governor, Reviews Strong Economic Growth and Industrial Projects

    President of Kazakhstan Kassym-Jomart Tokayev met with Asain Baikhanov, the governor of Pavlodar region, to review the region’s 2024 performance and discuss strategic priorities for the upcoming period.

    The meeting revealed that Pavlodar region experienced robust economic growth in 2024, with a 5.8% increase in regional GDP. Investments surged to 1.1 trillion tenge, marking a 38% year-on-year growth.

    Key industrial projects are currently underway in the region, including two major initiatives focused on processing gold-bearing concentrate and producing ferroalloys. A particularly significant development is the planned construction of three ferroalloy plants in Ekibastuz, with a combined capacity of 460,000 tons. These plants are expected to elevate Kazakhstan to the position of the world’s second-largest ferroalloys producer.

    The President emphasized the importance of sustaining the region’s economic momentum and ensuring effective execution of investment projects to support long-term national goals.