BR21882140
«Creation new technological solutions for the complex processing of metallurgical raw materials under «Industry 4.0» and Digital Twin concept»
Project Manager: Kenzhaliyev B.K.
Relevance: Modern production requires innovative technological solutions that allow involving substandard ore and technogenic raw materials into processing while ensuring low consumption of energy and material resources, also to develop wear-resistant coatings with increased tribotechnical characteristics. Development of the program based on Digital Twin will allow to select the technological mode.
Project goal: Creation of new technological solutions for complex processing of complex metallurgical raw materials in accordance with the concept of "Industry 4.0" and Digital Twin to analyze the developed technologies for beneficiation, pyro- and hydrometallurgical processing of substandard raw materials with extraction of non-ferrous, noble and rare metals, obtaining new materials.
Objectives of the project include:
-development of a method intended to produce molten fluxes for their use in the conversion of rich copper matte;
-development of hydrometallurgical extraction technology for noble and non-ferrous metals from refractory technogenic raw materials with preliminary treatment by special methods; demercurization of spent coal sorbents of gold extraction enterprises of Kazakhstan before their combustion for extraction of noble metals;
-development of technology of complex processing of titanium-containing products to obtain titanium dioxide and iron oxide pigments and rare earth element (REE) concentrate; obtaining wear-resistant coatings of complex multilayer composition based on modified titanium nitride;
-development of an effective technology for enrichment of hard-to-enrich sulfide, copper-molybdenum ores with the use of mercaptan-containing collectors derived from domestic petroleum products.
-creation of application software products to analyze the developed technologies based on the Digital Twin concept.
Based on the research results, the following will be published:
-at least 8 (eight) articles and/or reviews in peer-reviewed scientific journals in the scientific area of the program that are in the 1 (first), 2 (second) and/or 3 (third) quartile by impact factor in the Web of Science database and/or have a CiteScore percentile of at least 50 (fifty) in the Scopus database;
-at least 12 (twelve) articles in journals recommended by the Science and Higher Education Quality Assurance Committee;
-at least 3 (three) monographs or manuals in foreign and (or) Kazakh publishing houses;
-not less than 5 (five) intellectual property objects registered with the National Institute of Intellectual Property of the Republic of Kazakhstan.
Results achieved: Technological processing modes for processing technogenic gold-containing raw materials, copper-bearing ore and technogenic raw materials, industrial products of alumina production, phosphogypsum and substandard ilmenite, secondary magnesium-containing raw materials, producing castings from titanium alloys and high-alumina refractory products have been determined.
List of published works:
1 Kenzhaliyev, B.K.; Tussupbayev, N.K.; Abdykirova, G.Z.; Koizhanova, A.K.; Fischer, D.Y.; Baltabekova, Z.A.; Samenova, N.O. Evaluation of the Efficiency of Using an Oxidizer in the Leaching Process of Gold-Containing Concentrate. Processes 2024, 12, 973. https://doi.org/10.3390/pr12050973
2 Kenzhaliyev, B.; Ultarakova, A.; Toishybek, A.; Sadykov, N. Processing of Ilmenite Concentrate with High Chromium. Content // Processes 2024, 12, 1462. https://doi.org/10.3390/pr12071462
3 Kenzhaliyev B., Mukhanova A., Surkova T., Turysbekov D., Kaldybayeva Zh., Amanzholova L., Baltabekova Zh. Investigation of possibility of using sulfur-containing oil products as component compositions for production of flotation reagents // Canadian Metallurgical Quarterly, 1–11. https://doi.org/10.1080/00084433.2024.2423962
4. Rinat Abdulvaliyev, Almagul Ultarakova, Arailym Mukangaliyeva, Nina Lokhova and Kaisar Kassymzhanov Comparative Analysis of Acid Leaching for the Efficient Recovery of Lanthanum and Cerium from Phosphate Separations 2024, 11(10), 288; https://doi.org/10.3390/separations11100288
5 Kenzhaliyev, B.; Imankulov, T.; Mukhanbet, A.; Kvyatkovskiy, S.; Dyussebekova, M.; Tasmurzayev, N. Intelligent System for Reducing Waste and Enhancing Efficiency in Copper Production Using Machine Learning. Metals 2025, 15, 186. https://doi.org/10.3390/met15020186
6 Kenzhaliyev, B.; Trebukhov, S.; Volodin, V.; Nitsenko, A.; Kilibayev, Y.; Kolesnikova, O.; Linnik, X. Preliminary Removal of Mercury from Depleted Coal Sorbents by Thermal Vacuum Method with Associated Extraction of Precious Metal Composite. J. Compos. Sci. 2024, 8, 367. https://doi.org/10.3390/jcs8090367
7 Kenzhaliyev, B.; Fischer, D.; Temirova, S.; Ultarakova, A.; Baltabekova, Z.; Bakhytuly, N.; Smailov, K. Removal of Hexavalent Chromium Ions from Industrial Effluents Using Natural and Modified Diatomite, Taurite, Lewatit M500, and Activated Carbon // Processes 2025, 13, 997. https://doi.org/10.3390/pr13040997
8 Kenzhaliyev BK, Amangeldy BS, Mukhanbet A, Azatbekuly N, KoizhanovaA, Magomedov DR. Development of Software for Hydrometallurgical Calculation of Metal Extraction. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources.2025; 335(4):78-88. https://doi.org/10.31643/2025/6445.42
9 Кенжалиeв Б.К., Нурахов Е.С., Айбагаров С.Ж., Юсупова С.Ж. Integrated information system for demercurization and precious metal recovery from spent coal sorbents in kazakhstan’s gold extraction industry. Журнал "Вестник НИА РК" №4 2024 г. – С. 92-102 https://doi.org/10.47533/2024.1606-146X.007
10 Kenzhaliyev Bagdaulet Kenzhalievich, Surkova Tatiana, Dossymbayeva Zamzagul, Koizhanova Aigul Kairgeldyevna, Yessimova Dinara and Abdikerim Bekzat (2024). Bacterial oxidation in the hydrometallurgical process of copper extraction from copper-containing ore. Journal of Engineering Researcher and Lecturer, 3(3), 213–223. https://doi.org/10.58712/jerel.v3i3.173
11 Kenzhaliyev Bagdaulet Kenzhalievich, Surkova Tatiana, Dossymbayeva Zamzagul, Koizhanova Aigul Kairgeldyevna, Yessimova Dinara and Abdikerim Bekzat (2024). Modified sorbents based on natural mineral and its mechanical properties. Journal Pendidikan Teknologi Kejuruan, 7(4), 238–244. https://doi.org/10.24036/jptk.v7i4.39123
12 Б.К. Кенжалиeв, С.Ж. Айбагаров, С.Д. Бекеле, С.А. Квятковский, М.А. Дюсебекова. Development of a comprehensive software solution for processing high-sulfur, copper-poor concentrates in the copper smelting industry // "Вестник Университета Шакарима. Серия технические науки" №4(16) 2024 г. https://doi.org/10.53360/2788-7995-2024-4(16)-11
13 Кенжалиев Б.К., Койжанова А.К., Ерденова М.Б., Магомедов Д.Р., Смаилов К.М. Оптимизация извлечения меди из отвальных руд с использованием биохимических и химических методов окисления // Reports of the national academy of sciences of the republic of Kazakhstan. ISSN 2224-5227 Volume 2. Number 350 (2024), 167–182 https://doi.org/10.32014/2024.2518-1483.287
14 B.K. Kenzhaliyev, S.S. Temirova, D.E. Fisher, Zh.A. Baltabekova. Removal of hexavalent chromium from aqueous solutions by sorption with activated carbon. Review // Engineering Journal of Satbayev University. Volume 146 (2024), Issue 6,8-16. https://vestnik.satbayev.university/index.php/journal/article/view/1374
15 Kenzhaliyev, B., Mukhanova, A., Samenova, N., Toktagulova, K., Kaldybayeva, Z., Turysbekov, D., & Yussupova, S. (2025). Study of the dispersing properties of microemulsion mercaptan-containing collectors based on oil products. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources, 337(2), 85–94. https://doi.org/10.31643/2026/6445.20 https://kims-imio.com/index.php/main/article/view/538
16 Патент № 9109 от 10.05.2024. Способ переработки высокохромистого ильменита / Кенжалиев Б. К., Ультаракова А.А., Қаршыға З.Б., Лохова Н.Г., Касымжанов К.К., Муқаңғалиева А.Ө. https://ebulletin.kazpatent.kz/#/bulletin?timestamp=2024-05-10&bull_num=19&data_source=bulletin&language=ru
17 Патент № 9913 от 13.12.2024. Способ выщелачивания полиметаллического сырья https://ebulletin.kazpatent.kz/#/bulletin?timestamp=2024-12-13&bull_num=50&data_source=bulletin&language=ru
18 Патент № 9243 от 14.06.2024. Способ переработки некондиционного ильменита с повышенным содержанием хрома
19 Патент № 8335 от 06.10.2023. Печь для непрерывной плавки сульфидных материалов в жидкой ванне
20 Кенжалиев Б.К., Мамаева А.А., Паничкин А.В., Аубакирова Р.К., Кенжегулов А.К. Процессы диффузии и образования фаз в двойных и многокомпонентных системах на основе металлов / Монография. – Алматы, КазНИТУ им. К.И. Сатпаева. 2024 г., - 524 с. ISBN 978-601-7042-26-4
