Murat Kuanyshev

The aim of this study was to investigate the effect of reduction roasting parameters on the phase transformations of the Ushkatyn-III ferruginous manganese ore and the efficiency of subsequent magnetic separation. The experimental procedure included preliminary high-intensity magnetic separation, reduction roasting at 650 °C for 3–5 h using 20–30 wt.% coal as the reducing agent, and low-intensity dry magnetic separation at magnetic field intensities of 0.1–0.6 T. Chemical composition was determined by standard analytical methods, while phase composition was analyzed by X-ray diffraction (XRD). Preliminary magnetic separation increased the manganese content in the magnetic pre-concentrate to 30.71–35.09 wt.%. The optimum results were obtained after roasting for 5 h with 30 wt.% coal, followed by magnetic separation at 0.2 T, producing a low-iron concentrate containing 33.26 wt.% Mn and 0.67 wt.% Fe, with a manganese recovery of 87.79% and an Mn/Fe ratio of 49.6. XRD analysis confirmed the partial reduction of hematite to magnetite (Fe₃O₄), providing the basis for efficient magnetic separation. The proposed process offers an effective approach for upgrading low-grade ferruginous manganese ores for manganese ferroalloy production.

The production of refined ferrochrome is accompanied by the formation of self-disintegrating slags caused by the β→γ-Ca₂SiO₄ polymorphic transformation during cooling, resulting in environmental and technological problems. This study aimed to develop and validate a technology for long-term stabilization of refined ferrochrome slags using remelted and desulfurized borate ore (RDBO) from the Inder deposit as an alternative to colemanite. Thermodynamic modeling, X-ray diffraction (XRD), scanning electron microscopy (SEM), and pilot-industrial trials were conducted to evaluate phase transformations, microstructure formation, and slag stability. The results showed that the addition of boron oxide promoted the formation of stable borate phases, primarily CaB₄O₇, and reduced the content of unstable Ca₂SiO₄ phases. Autoclave testing under saturated steam conditions (400 kPa, ~180 °C, 24 h) demonstrated complete preservation of structural integrity in all RDBO-stabilized samples, with an average mass loss of 0.19 ± 0.01%, whereas colemanite-stabilized slags exhibited cracking and partial disintegration. The stabilization effect was achieved at a B₂O₃ content of 0.17–0.47 wt.% without boron contamination of ferrochrome. The proposed technology ensures long-term slag stability and enables the utilization of stabilized slag as a technogenic material for road construction.