Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex use of mineral resources

Study of the suitability of industrial raw material resources as additives for Portland cement

G.B. Begzhanova — 2025-11-25

This research investigates the potential of utilizing industrial technogenic waste materials as hybrid mineral additives in the production of composite Portland cement (CPC), aiming to reduce clinker consumption and promote environmentally friendly construction practices. The studied materials include active ash and slag (AAS) from the Angren thermal power plant, microsilica (MS), and processed steelmaking wastes such as ladle slag (LS), furnace slag (FS), and recycled steel slag (RSS) from Uzmetkombinat JSC. The chemical, mineralogical, and mechanical properties of these materials were characterized in accordance with national and international standards. Compressive strength tests and lime absorption measurements evaluated their pozzolanic and hydraulic activities. Experimental results demonstrated that AAS exhibited the highest activity, capable of replacing up to 45% of clinker without compromising mechanical strength. When combined with less active components (MS, RSS, FS, and LS), hybrid additives showed synergistic effects. Among these, the AAS+MS blend had the most significant pozzolanic effect, evidenced by reduced calcium oxide (CaO) concentration in the surrounding liquid and lower solution alkalinity. The statistical validation using the Student’s t-test confirmed the effectiveness of each additive, with t-values significantly exceeding the threshold required to classify them as active mineral additives. The findings support the development of “green” CPCs using hybrid additives derived from local industrial waste, offering a sustainable alternative to traditional raw materials. These formulations can significantly reduce carbon dioxide emissions, energy consumption, and natural resource depletion while maintaining cement performance, thus aligning with global trends toward low-clinker and low-carbon construction materials.

Extraction of P₂O₅ from the mineralized mass of the Central Kyzylkum using acidic wastewater generated from cotton soapstock processing: scientific analysis based on equilibrium principles

U.S. Baltayev — 2025-11-25

This study explores the prospects of extracting phosphorus pentoxide (P₂O₅) from the mineralized mass of the Central Kyzylkum region using acidic wastewater (AWW) derived from cottonseed soapstock processing. The acidic components within the AWW were found to facilitate the decomposition of solid-phase phosphorite material. Experiments were conducted at 333 K under varying AWW-to-mineralized mass (AWW:MM) ratios ranging from 100:10 to 100:40. The concentration of P₂O₅ was determined using a photometric method at a wavelength of 440 nm. The research was based exclusively on the analysis of the solid phase, where the extent of the reaction was assessed through the quantity of precipitate formed. It was demonstrated that an increase in pH had a direct effect on P₂O₅ extraction. The reduction in CaO content followed an exponential trend, while the P₂O₅ release exhibited a logarithmic relationship with pH. The equilibrium reactions between ions were interpreted within the framework of chemical mechanisms. Experimental results were expressed through graphical analysis and regression modeling using OriginPro 2021. The obtained data were mathematically modeled with high reliability, as indicated by coefficients of determination (R²) exceeding 0.95. This approach offers a cost-effective, waste-based alternative technological method for phosphorus extraction, utilizing industrial by-products while maintaining environmental and economic feasibility.

Polymer-bitumen compositions for improving the energy efficiency of road construction

A.G. Syzdyk — 2025-11-25

This article examines the effect of two types of polypropylene (H030 and H350) and petroleum residue on the bitumen modification process. Bitumen modification is one of the key methods for improving its physical and mechanical properties and enhancing the quality of road pavement. Currently, bitumen modification is widely used in road construction, playing a crucial role in improving its quality and energy efficiency. Studying the effect of polymers on the mechanical stability of bitumen is a relevant issue in increasing the durability of road surfaces. During the study, six different concentrations of polypropylene H030 and H350 were introduced into bitumen samples, and their main characteristics were compared. The obtained results demonstrated that polypropylene significantly alters the properties of bitumen, contributing to increased strength and durability of road pavements. Furthermore, the addition of petroleum residue enhances the rheological properties of the bitumen mixture, improving its adhesion. These studies provide essential data for improving bitumen used in road construction. The research results indicate that the use of polymer-modified bitumen increases the wear resistance of road surfaces, reduces crack formation, and enhances resistance to climatic factors. This, in turn, extends the service life of road pavements and reduces road maintenance costs. Long-lasting pavements help decrease energy consumption for bitumen production and road construction. The obtained data expand the possibilities for the effective use of polymer-modified bitumen mixtures in asphalt concrete production. Thus, the compatibility of bitumen and polypropylene has been studied, and their optimal compositions have been determined.

Innovative Adsorbent Materials for Efficient Silicon Extraction from Industrial Waters: A review

M. Kylyshkanov — 2025-11-26

Silica fouling reduces the effectiveness and durability of membrane-based treatment systems, and silicon contamination in industrial water streams poses ongoing operational issues. With an emphasis on their processes, drawbacks, and applicability for various silica species, this article provides a comparative examination of the main silica removal technologies: ion exchange, reverse osmosis (RO), ultrafiltration (UF), electrocoagulation (EC), adsorption, and lime softening. Although they need a significant amount of chemical input and pH control, lime softening and ion exchange are efficient for dissolved silica. RO requires thorough preparation and offers broad-spectrum separation, although it is susceptible to silica scaling. While UF works well with colloidal and particulate silica, it is unsuccessful with monomeric forms. EC achieves excellent removal rates with less sludge by combining electrochemical destabilisation and crystallisation. Adsorption provides variable selectivity, low energy consumption, and compatibility with membrane systems, especially when employing tailored materials like activated alumina, iron oxide-coated media, and functionalised hybrids. In addition to outlining important techno-economic considerations for scaling up silica extraction methods in intricate industrial water matrices, the paper highlights new developments in adsorbent design, such as surface modification, hierarchical porosity, and regeneration techniques.

Predicting Copper Production Cycles in Hydrometallurgy with Interpretable Machine Learning

B.K. Kenzhaliyev — 2025-10-16

Accurate production forecasting in industrial hydrometallurgy is essential for process optimization yet is often hindered by the scarcity of extensive historical data. This study demonstrates the effectiveness of classical machine learning models as a data-efficient and interpretable alternative to complex deep learning methods for predicting total copper mass. We evaluated four models—Random Forest, Gradient Boosting, Decision Tree, and Linear Regression—using a methodology centered on two key strategies: synthetically expanding a limited 150-day dataset into 10,000 simulated cycles (approximately 1.5 million data points) via data augmentation, and engineering 10-day lag features to provide the models with a temporal perspective for a 10-step-ahead forecasting task. The results revealed exceptional predictive accuracy, with ensemble techniques proving superior. The Random Forest model emerged as the top performer, achieving an R² of 0.974, an MAE of 0.088, and an RMSE of 0.111, closely followed by Gradient Boosting (R² of 0.971). All models successfully captured the distinct 150-day cyclical dynamics of the production process, showing a near-zero phase lag (0.00 ± ≤0.05 days). While performance on new, independent data requires further validation, this work establishes a robust and transparent framework for developing reliable forecasting tools in data-limited industrial environments.

Use of Industrial By-products from Metallurgical Production for the Development of Heat-Resistant Building Mixes and their Molding in an Improved Device

A.T. Khabiyev — 2025-10-16

In the context of the increasing volume of industrial waste and stricter environmental requirements, the urgent task is to efficiently process them to produce products with high added value. In this work, the composition of industrial products of vanadium production formed during the hydrometallurgical processing of rare metals is investigated, and the possibility of their use for the production of heat-resistant building mixes is substantiated. A comprehensive analysis, including X-ray, X-ray fluorescence, and scanning electron microscopic methods, revealed a high content of silica, aluminum oxides, and refractory minerals that determine the heat resistance of the material. Optimal compositions of building mixes based on Portland cement, liquid glass, and chamotte have been developed, providing compressive strength up to 45 MPa and resistance to thermal cycling at temperatures up to 1800 ° C. The design of a device for forming building blocks based on industrial waste from metallurgical production by vibration pressing is proposed, designed to ensure high density and geometric stability of products. The results obtained confirm the possibility of complex industrial waste disposal with the simultaneous creation of environmentally safe, durable, and heat-resistant building materials used in energy, metallurgy, the chemical industry, and civil engineering.

Artificial graphite from Shubarkol coal obtained by sublimation of carbon atoms into the gas phase followed by desublimation into high-purity graphite

Zh.T. Aimenov — 2025-11-18

This article discusses a plasma-chemical method for producing high-purity graphite from an air suspension of low-ash coal particles from the Shubarkol deposit in Kazakhstan. The technological process is based on the ability of carbon to transform from a solid to a gaseous state, bypassing the liquid state. This means it sublimes at high temperatures and desublimes as the temperature of the gaseous medium in the reactor zone decreases. The use of a graphite catalyst allows for controlled formation of the graphitized material. Atomic carbon graphitization occurs over a wide temperature range. It was established that graphite obtained in high-temperature reactor zones is purer than graphite obtained in reactor zones close to 500°C. This feature of the graphitization process enables product classification by quality. The design of a reactor based on sublimation and desublimation processes for graphite production is discussed. The use of a high-frequency electromagnetic zone in the plasma-chemical reactor design allows for controlled graphitization of atomic carbon, intensifying desublimation processes over a graphite powder catalyst. The plasma-chemical apparatus design includes a dust collection system and carbon monoxide neutralization, which can occur due to variations in the component proportions in the feedstock, which includes carbon powder, graphite powder catalyst, and carbon dioxide. The developed apparatus can be used to produce a sorbent – thermochemically expanded graphite – from graphite by varying the operating mode. The aim of this research is to develop a plasma-chemical technology for producing graphite from coal based on sublimation and desublimation processes in a single reactor, with the separation of impurities during the graphitization of carbon atoms over a graphite catalyst.

Redistribution of rock pressure and deformation of the rock mass in the Karaganda coal basin

R.A. Mussin — 2025-11-18

The study examines the redistribution of rock pressure and associated deformation processes in the Karaganda Coal Basin. It focuses on the geometry and parameters of the abutment, unloading, and disintegration zones around underground workings, and on their influence on gas-dynamic phenomena. The methodological basis combines a critical review of current geomechanical models, calculation–graphic nomograms for estimating zone width as a function of mining depth and seam thickness, and schematic construction of high-stress regions from the boundaries of the goaf at limiting angles of 75–90°. It is shown that, with increasing depth up to about 500 m, the zone configuration becomes wedge-shaped with a tendency to narrow downward, while increasing seam thickness expands the affected areas. Lithology controls the localization of hazardous zones: weakly bedded argillites and siltstones accelerate loosening and loss of stiffness, whereas stronger sandstones form dome-like stress concentrations with elevated likelihood of sudden outbursts and rockbursts. As a verification case, an episode of a sudden coal-and-gas outburst was analyzed. The observed failure boundaries are consistent with the calculated wedge-shaped high-stress zone, supporting the validity of the chosen approach within the stated assumptions. The practical significance lies in refining threshold conditions that trigger mandatory comprehensive forecasting at depths exceeding ~400 m, justifying regular instrumental monitoring to validate calculations, and adjusting barrier-pillar parameters about seam thickness and depth. The findings can be applied to the planning and safe execution of longwall and development operations under outburst-prone conditions.

Innovative technologies for paraffin deposit removal in oil tubing to enhance oil recovery: a mechanical approach

Zh.N. Alisheva — 2025-11-18

Asphaltene - resin - paraffin deposits (ARPD) on the inner wall of production tubing shorten service intervals, elevate operating expenditures, and frequently induce downtime at mature fields. This paper presents the design and field performance of a rod-driven in-well scraper that provides continuous tubing cleaning during routine sucker-rod operation without chemical dosing or surface interventions. The scraper sub is inserted into the rod string and is compatible with Ø73 - 89 mm tubing and Ø19 - 22 mm rods. Performance was evaluated on a before/after basis using the inter-cleaning period (ICP), downtime, and annual cleaning costs, with extrapolation to multi-well programs. Field deployments of model CP TP ST 01KZ achieved an ICP of 144 - 280 days with zero cleaning-induced downtime (0 days yr⁻¹). Annual cleaning costs were ~0.265 million KZT per well (scheduled service only), which is ≈31× lower than hot-wash budgets on the same asset. The implied per-well saving is ≈7.94 million KZT yr⁻¹; for a 50-well program, this corresponds to ≥397 million KZT yr⁻¹ in avoided expenditure. Continuous in-well action of the reciprocating toothed head on each rod stroke disrupts the boundary wax layer and limits deposit regrowth between services, eliminating periodic thermal/chemical treatments and their logistics. The subassembly mass (≈30 kg) permits installation with standard handling; the pump string configuration is unchanged apart from the insertion of the scraper section. Compared with thermal, chemical, and batch mechanical methods, the technology extends service intervals, removes cleaning-related shut-ins, and compresses the cleaning budget to a predictable, low annual service cost. The results support routine use of rod-driven scraping for ARPD control in wax-prone wells and provide quantitative guidance for field-scale rollout and further optimization (wear resistance, centralization tolerances, and application in deviated completions).

Comparative Analysis of Mathematical Models of Drilling in Heterogeneous Geological Sections

J.B. Toshov — 2025-11-19

This paper presents a comparative analysis of four main types of well drilling models in heterogeneous geological sections: mechanical-mathematical, energy, kinematic, and empirical. It is shown that each group of models focuses on different aspects of the process: the physics of bit-rock interaction (mechanical-mathematical approach), the energy efficiency of rock mass destruction (energy), the trajectory and movement of the tool (kinematic), as well as statistical patterns and the prediction of complications (empirical). The interaction between the bit and the rock is considered depending on their physical and mechanical properties. A comparison of the rotation speed of the rotor and bit is provided depending on the rock hardness. Based on a review of modern publications and the practical experience of leading service companies (Equinor, Schlumberger, Halliburton), the strengths and weaknesses of each approach are identified, and the need for their integration is substantiated. It is established that the integrated use of models of different classes allows not only to describe and explain phenomena but also to manage the drilling process in conditions of high geological variability.