Metallurgical Complex Research Articles

Utilizing copper waste to develop silicon-carbon anode materi als for lithium-ion batteries

This study dedicated to a novel method for synthesizing silicon-carbon (Si/C) and silicon dioxide-carbon (SiO2/C) nanocomposite anodes for lithium-ion batteries, utilizing industrial copper slags from the Almalyk Mining and Metallurgical Complex as a cost-effective source of SiO2. The synthesized nanocomposites address key challenges in lithium-ion battery anodes, including the volumetric expansion of silicon and its low conductivity, by leveraging the high lithiation capacity of silicon combined with the structural stability and conductivity of carbon. Amorphous SiO3 was extracted from copper slags via ammonium fluoride (NH4F) treatment and subsequently reduced to metallurgical-grade silicon through carbothermal reduction. The resulting SiO2/C and Si/C composites were thoroughly characterized using SEM, XRD, and electrochemical analyses, demonstrating improved electrochemical performance, favorable particle size distribution, and stability. This approach not only reduces material costs but also promotes environmental sustainability by repurposing industrial waste, offering promising candidates for high-performance lithium-ion battery anodes.

Research on improving zinc concentrate roasting technology at the Zinc Plant of JSC Almalyk Mining and Metallurgical Complex

Research on improving zinc concentrate roasting technology at the Zinc Plant of JSC Almalyk Mining and Metallurgical Complex

Diatom Diversity from Watercourses of North-Eastern Kamchatka with Description of One New Species

A study of diatoms in eight watercourses (four spawning rivers and four streams) in the area of the Ozernovsky Mining and Metallurgical Complex (MMC) on the Kamchatka Peninsula was carried out for the first time. A total of 174 taxa were identified, and a comparative analysis of periphyton species diversity at the sampling stations was carried out. A new species for science was proposed: Gomphonema anissimovae Glushchenko, Kezlya & Kulikovskiy sp. nov. The composition and quantitative characteristics of plankton were analysed only in samples collected from rivers. It was shown that all rivers are oligotrophic in terms of phytoplankton biomass. The work includes lists of taxa with indication of their abundance, as well as illustrative material of found diatom taxa, which will provide an opportunity to monitor changes in planktonic and periphyton microalgae communities in the studied watercourses in the context of potentially high anthropogenic load from industry.

Monitoring of suspended matter in the Dnipro River within Zaporizhzhia city, the main trends of 2022

The article presents the results of monitoring observations on the temporal distribution of the qualitative and quantitative components of the Dnipro River suspended matter within Zaporizhzhia city. The research on the territory of this powerful industrial center of Ukraine with a developed metallurgical complex was carried out from 2015 up to 2019 and from the end of 2021 to the present time. The main task of the research was determining the distribution of iron and a group of heavy metals of anthropogenic origin in the composition of the river suspension, and identifying the connections of their concentrations and forms with the natural conditions of the region. Sedimentary matter from the water flows of Dnipro River within research area was sampled once per month using sedimentary traps developed by authors. The methods of electron microscopy (with microprobe analysis) and laser diffraction analysis were used to study the suspension granulometric and chemical composition in the Center for Shared Use of Scientific Equipment of the IGS NASU. SEM studies were carried using scanning electron microscope SEM JEOL-6490 LV (Jeol Ltd., Japan) with an energy dispersive spectrometer of the X-ray microanalysis system INCA Energy+ (Oxford Instruments plc., Great Britain). Particle size analysis was determined using the laser particle size analyzer Mastersizer 2000 with a Hydro 2000S wet dispersion module (Malvern Ins. Ltd, UK).The study results of the samples taken in the first year of hostilities in Ukraine revealed a number of features which were not observed in the previous series of studies. Those peculiarities are the following ones: reduction in the intensity of sedimentary matter accumulation; decrease of technogenic components in the suspension content (in particular, the amount of ferrous metals, changes in the ratio of condensed and dispersed iron particles of silt size, as well as the component composition of fragments of alloys of non-ferrous and ferrous metals). The obtained results may indicate the sensitivity of the component composition of the suspension to changes in the external environment in general, as well as the significant impact of the anthropogenic component on the distribution of iron in suspended matter.

Thermodynamic aspects of WO3 tungsten oxide reduction by carbon, silicon, aluminum and titanium

The development and research of new materials for machine parts of the mining and metallurgical complex by the method of surfacing with flux cored wire has a lot of attention nowadays. Flux cored wires are widely used for surfacing of steels with high wear resistance, in which reduced tungsten in the form of ferroalloys, ligatures and metal powder of various degrees of purity are used as fillers. However, due to the scarcity and high cost of tungsten, its rational use is an urgent task. For practical application, the technology of surfacing with tungsten-containing flux cored wire is of interest; using it the maximum extraction of tungsten into the deposited layer is achieved due to reduction processes in the arc. In order to increase the beneficial use of tungsten, the technologies of indirect alloying with tungsten during surfacing under the flux of flux cored wires, in which tungsten oxide is used as a filler on the one hand, and reducing agent – on the other, deserve consideration. It can be expected that during arc discharge, tungsten and (or) chemical compounds of tungsten with reducing agents can be formed during the surfacing process. This paper presents the results of a comparative analysis of the thermodynamic processes of tungsten oxide reduction by carbon, silicon, aluminum and titanium during arc discharge occurring during surfacing with flux cored wires under a layer of flux. The thermodynamic analysis of 41 reactions in standard states showed that the presence of reducing agents (carbon, silicon, aluminum, titanium) in the flux cored wire used for surfacing will contribute to the formation of silicides and tungsten carbides, and, possibly, tungsten itself. It was determined that the best state for the participation of tungsten oxide in reactions in the arc is WO3(g) gaseous state.

Пути повышения конкурентоспособности металлургического комплекса России

The authors explore ways to improve the competitiveness of Russia's metallurgical complex on the example of two leading companies in the industry - PJSC Severstal and PJSC Magnitogorsk Iron and Steel Works. The article analyses the strategies, financial results and methods used by these companies to strengthen their market positions, including investments in production modernisation, the introduction of innovative technologies, the development of strategic partnerships and a focus on environmental sustainability. The key highlights and achievements of each company are discussed, as well as their contribution to the development of the Russian steel industry. The article concludes by highlighting the key factors contributing to successful competition in the global market and offers recommendations to further improve the competitiveness of the Russian metallurgical complex.

Пути повышения конкурентоспособности российских металлургических компаний

The authors explore ways to improve the competitiveness of Russian metallurgical business on the example of two leading companies in the industry - PJSC Severstal and PJSC Magnitogorsk Iron and Steel Works. The article analyses the strategies, financial results and methods used by these companies to strengthen their market positions, including investments in production modernisation, the introduction of innovative technologies, the development of strategic partnerships and a focus on environmental sustainability. The key highlights and achievements of each company are discussed, as well as their contribution to the development of the Russian steel industry. The article concludes by highlighting the key factors contributing to successful competition in the global market and offers recommendations to further improve the competitiveness of the Russian metallurgical complex.

A PRIORI ASSESSMENT OF THE EFFECTIVENESS OF OCCUPATIONAL SAFETY MANAGEMENT SOLUTIONS

The article analyzes the problems of effective management of labor safety at enterprises. It is noted that the search for methods of justifying management decisions in this area remains relevant from the point of view of theoretical consideration of existing developments and the development of practical recommendations for their implementation at enterprises. Despite the presence of a large number of different approaches to improving management efficiency, based on the theory of decision-making and expert methods, taking into account the cost of implementing this or that variant of the decision, in the vast majority of cases, remains overlooked. A method of conducting an a priori assessment of the effectiveness of decisions is proposed, which involves the formation of a set of alternatives of management decisions, their subsequent expert assessment, as well as the assessment of the cost of their implementation. For a reasoned choice of alternatives, it is suggested to use the indicator of their effectiveness, which is calculated as the ratio of expert assessment to the conditional cost of implementing the alternatives. An example of the application of the developed methodology for one of the enterprises of the mining and metallurgical complex for the justification of measures to reduce the risk of a traumatic event "Contact with an open flame, hot substance or surface" is considered. An alternative is recommended for implementation, which involves increasing the level of technical control of dangerous production factors. For the rational implementation of the proposed methodology at the enterprise, it is necessary to ensure the functioning of the system of accounting and analysis of production factors for the possibility of using these data in the formation of problems that need to be solved. In addition, the implementation of the methodology involves the possibility of involving qualified experts for an objective a priori evaluation of alternatives

Change in deformation mechanism to change TRIP to TWIP strengthening in the class of 304 austenitic stainless steel sheets by trapezoidal wavy-rolling process

ABSTRACT Strengthening of steels through twinning-induced plasticity (TWIP) has several advantages like high-strength and high-ductility combination over the transformation-induced plasticity (TRIP) mechanism which gives high strength, low ductility and product phase of martensite in the single phase solid solution of austenitic matrix. But, development of TWIP effect will be more difficult unless the steel contains high stacking fault energy (SFE) (>20mJ/M2), fine grain structure and high manganese alloying (15–30 wt.%). These are very expensive processes and susceptible to metallurgical complexity in the austenitic stainless steels. Therefore, new processing technology was developed for strengthening of the austenitic stainless steel sheets by trapezoidal wavy rolling (TWR). Type 304 austenitic stainless steel was selected for this study which is known as martensite transformation, a dominant hardening mechanism due to low SFE and coarse grained structure. Wavy deformation-induced results have been studied through strain hardening behaviour by flow stress-strain curves and microstructural changes by atomic force microscope (AFM), and phase transformations by using X-ray diffractometer (XRD) analysis. It is found that this process introduced changes from TRIP to TWIP mechanism by forming plenty of mechanical twins and shear bands type structure at initial stage of deformations and partial martensite is observed in advanced stage.

High-fidelity level-set modeling of diffusive solid-state phase transformations for polycrystalline materials

The formation of microstructures in metallic alloys during hot metal forming involves simultaneous metallurgical complex phenomena. Traditional high-fidelity numerical frameworks used on the polycrystalline scale tend to focus on single-phase microstructures or isolate phase transformations from grain boundary migration mechanisms. The level-set method is highlighted as effective in proposing a global framework for modeling multiphase polycrystalline materials and diffusive solid-state phase transformations. This framework includes novel techniques for efficient large-scale microstructural representation, strong coupling with ThermoCalc software for real-time thermodynamic data, application for ternary alloys and beyond by taking solute drag aspects, and the use of advanced nucleation models. Numerous applications are then illustrated.

RESEARCH WORKS OF METALLURGICAL EQUIPMENT USING SIMULATION METHODS

The wear and tear of the main production facilities of enterprises of the metallurgical complex requires not only renewal, but also constant modernization of morally outdated equipment in the conditions of active production. The main equipment of the flow lines of wide-scale rolling mills include winders, the quality of which depends on both the rhythm of the rolling equipment and the quality of the material shipped to the consumer. Simulation modeling of the winding process of the hot-rolled staff made it possible to establish the possibility of torsional oscillations in the winding drum drive. Further analysis of the form of the resulting oscillations will allow to create prerequisites for the study of forced oscillations occurring in the winding drum drive and to determine the most unfavorable technological mode from the point of view of dynamic component loads.

Occupational prevalence rates in metallurgists in the Sverdlovsk Region

Introduction. The previous analysis conducted for 2003–2022 showed ferrous industry employing over twenty five thousand people to make the most contribution to occupational disease incidence rates in the Sverdlovsk Region since 68.6 % of its workers are affected by industrial exposures above occupational safety standards. The purpose of the study was the analysis of occupational disease incidence in workers of a ferrous metal processing plant of the Sverdlovsk Region and assessment of the impact of adverse factors of the work environment and industrial processes on its rates.
 Materials and methods. Long-term occupational disease incidence in workers of the ferrous metal processing plant has been analyzed by the causative agent, nosology, age, gender, and job. Data of the reporting form No. 1-T (working conditions) for the study period have been scrutinized; comparative data evaluation by working conditions and occupational disease incidence rates has been made.
 Results. High incidence rates of work-related diseases in the metallurgists indicate to a significant proportion (70 %) of them to be exposed to occupational hazards. The established 20-year rate at the enterprise was 5.6 and 1.6 times higher than the regional and Russian averages in this industry, respectively. Increased gas and dust levels in the workplace air remain the leading health risk factors in ferrous metallurgy.
 Limitations. The limitation of this study was the lack of annual data on workers by job preventing calculation of job-specific disease incidence rates per 10 thousand workers.
 Conclusion. Despite the substantial modernization of the metallurgical complex, metal processing technology still does not comply with safety standards, thus requiring the development and implementation of science-based preventive measures aimed at maintaining workers’ health.

Moss biomonitoring of air quality linked with trace metals pollution around a metallurgical complex in Elbasan, Albania

Moss biomonitoring of air quality linked with trace metals pollution around a metallurgical complex in Elbasan, Albania

Investigation of physicochemical characterization and magnetic enrichment of iron ore from Sidi Maarouf deposit

The establishment of a new metallurgical complex in Bellara, located in El-Milia in the Jijel region, is geographically advantageous due to its proximity to the Sidi Maarouf deposit (Algeria). This proximity has been a fundamental motivation for the completion of the current study. The object of research is the quality of iron products from Sidi Maarouf. The research is aimed at developing a treatment process aimed at improving the quality of iron products from Sidi Maarouf, while reducing the impurities of quartz and clay present in this ore. This approach will be based on an approved technological treatment scheme, implemented through an experimental approach to ensure reliable results that meet the requirements of the steel industry. The problem issue revolves around the difficulties encountered in the production of steels due to the natural characteristics of the raw material. In the absence of a physico-chemical characterization of the Sidi Maarouf iron ore deposit, samples taken undergo a series of thorough analyses, including microscopic examinations, X-ray diffraction (XRD), as well as additional chemical analyses using X-ray fluorescence (XRF). The identified minerals are predominantly composed of hematite in terms of iron. As for the gangue, it is mainly composed of calcite and quartz. Through to the pre-treatment process involving washing, we have successfully removed lightweight particles, resulting in a concentrate containing dense particles. This approach was crucial in achieving satisfactory results during the high-intensity dry magnetic separation. As a result of the research it is shown that the enrichment of the Sidi Maarouf iron ore through high-intensity dry magnetic separation, a final concentrate was obtained with a Fe2O3 content exceeding 67 %, along with a significant reduction in silica impurities to 0.92 % and alumina to 0.77 %. It was concluded that this concentrate, derived from the -1+0.5 mm fraction and obtained under a current intensity of 12 A, meets the requirements of the steel industry. Following the work carried out, it is found that the methods of valorization of iron ore through mineralogical processes consistently require a high level of efficiency and performance in terms of equipment and characterization of the products obtained. In the future, iron ore processing will be conducted using innovative methods, integrating advanced technologies to enhance its characteristics while adopting environmentally friendly practices.

FLOT-ART: An integrated plant optimization tool for the flotation of copper and copper–gold ores

Conventional flotation plant optimization procedures for copper and copper–gold ores have served the industry well over decades. But with the present trend in declining ore grades along with increase in metallurgical complexity, many flotation operations are experiencing significant challenges in sustaining design or operational budgeted recovery and concentrate quality targets. The need to use non-conventional water sources like brackish, sea water, and recycled process water has exacerbated the problem. Also with the emergence of various large mechanical cells and new non-mechanical flotation technologies, the ongoing use of traditional plant operational strategies is further adding to the challenges.This paper discusses an integrated plant optimization tool for the flotation of complex copper and copper–gold ores in addressing the present challenges, branded as FLOT-ART (Flotation Advanced Recovery Technology). This includes a cohesive flotation plant optimization approach starting with a mineral surface preparation step in grinding followed by advanced mineral-specific electrochemistry and cell hydrodynamics based circuit operation. This approach then allows an ore-specific grade-recovery control strategy for optimum flotation performance. This development is based on extensive greenfield projects, brownfield plant expansion studies along with operational optimization programs involving bench and plant campaigns. Principles of the FLOT-ART optimization system will be presented in this paper along with some commercial applications in the flotation of copper and copper–gold ores.

Pollution indices as useful tools for comprehensive evaluation of the soil contamination degree in the vicinity of mining and metallurgical complexes

Soil pollution levels in the copper mining and metallurgical area were evaluated at 14 sampling sites in the City of Bor and its surroundings in regard to Al, As, Cu, Fe, Pb and Zn contents, as well as single and integrated pollution indices. The significance of single pollution indices provides information about pollution by a specific element, while integrated pollution indices offer an insight into cumulative pollution by the examined elements. The mean soil concentrations of As, Cu, Pb and Zn were several times higher than the world average values. The exceedances of soil remediation values were most pronounced for As (at seven sites) and Cu (at eleven sites), more than 3 and 13 times, respectively. According to the geoaccumulation index, the enrichment factor and the contamination factor, the highest soil contamination was with As and Cu, especially at the urban-industrial site. Pollution load index, Nemerow pollution index and the improved Nemerow index confirmed that the most contaminated soils were from the sites in the vicinity of the metallurgical complex and flotation tailing ponds, as well as from the sites in the prevailing wind directions compared to the less polluted soils affected by the ore mining processes. The areas affected by the serious cumulative contamination from the pyrometallurgical copper production need continuous pollution prevention, monitoring and remediation measures.

Минимизация риска загрязнения селитебных зон пылью при открытой добыче руд

The sphere of activity of the mining and metallurgical complex of the Kursk Magnetic Anomaly included populated areas and agricultural objects. An air dusting zone with a radius of tens of kilometers was formed around openpit mining pits. During explosions in quarries, dust clouds are formed, from which fine mobile dust is dispersed. Therefore, the regions of the Kursk magnetic anomaly are characterized by the accumulation of chemical elements, including hazard classes 1–2. The dustiness factor in ecosystems complicates the living conditions of the population, which experiences the chemical effect of natural leaching of ore mining and processing products. Disturbance in the balance of the pro-oxidant-antioxidant system can cause a variety of diseases. A radical measure to prevent disease is to reduce the volume of mobile dust during ore mining in quarries. The parameters of rock destruction by explosion depend on the crushing energy intensity, above which the action of the charges goes into the ejection zone with the formation of mobile dust. Increasing the height of the ledge reduces the energy intensity of the explosion (by reducing the consumption of explosives) and the release of mobile dust. Both convective and diffusion processes occur in a dust cloud. Quarry emissions contain metals that form toxic compounds that cause soil degradation. The reaction of living matter to the effects of pollutants is predictable, which can be the basis for regulating the state of the environment. Improving the living conditions of the biota and population in the vicinity of mining sites can be achieved by adjusting the ore mining technology. To reduce the yield of mobile dust, a combined scheme of explosive ore breaking with differentiation of the process of destruction of the base of the ledge and the main mass is recommended.

Analyzing the Directions of Transformation of the Mining and Metallurgical Complex of Ukraine

Analyzing the Directions of Transformation of the Mining and Metallurgical Complex of Ukraine

ФОРМУВАННЯ ВАНТАЖНИХ ПЕРЕВЕЗЕНЬ ЗАЛІЗНИЧНИМ ТРАНСПОРТОМ УКРАЇНИ В УМОВАХ ВОЄННОГО СТАНУ

The article analyzes trends in freight traffic within 2022-2023 years. The data on the number of dispatched freight cars and volumes of cargo transportation have been processed. Changes in the logistical component since the beginning of the invasion of the aggressor country are considered. An important logistical component should include the change of routes due to the destruction of railway tracks and fixed track structures, blockouts of ports. Since the full-scale Russian invasion of Ukraine railway logistics has undergone drastic changes, i.e., a large number of cargoes went to western cross-overs instead of ports. As reported by the State Customs Service, the export of goods from Ukraine in 2022 decreased by 35% to 44.2 billion dollars. As usual, the agro-industrial and mining and metallurgical complexes, which provided more than ⅔ of goods and more than half of total exports, became the leaders in terms of export volumes under the martial law period. The leaders in export value among goods are grain crops, sunflower oil and ferrous metals. Based on the results of 2022, the export of metal collapsed more than three times, to 4.5 billion dollars. The mining and metallurgical complex of Ukraine suffered from the war much more than other sectors of the economy. About 40% of metallurgical capacities were captured or destroyed in Mariupol, namely, metallurgical plants of the MMK named after Ilich and PrJSC «Azovstal», the average loading of other capacities in 2022 was at the level of 30%. Plus, unlike the grain market, which has the opportunity to export its products through large ports even despite the unstable operation of the «grain corridor», the main routes for the mining and metallurgical complex still remain the western cross-overs and the Danube. It was determined that, against the background of the above-mentioned factors, the railcar-building industry in Ukraine underwent changes in the production of freight wagons in 2022-2023, that is, fewer orders for open-top wagons, and the active construction of platforms and other special-purpose wagons, as well as the production of bogies for the European track. Despite the difficulties, some of the domestic enterprises quickly found their way in today's realities and even managed to increase production. It has been established that the main domestic manufacturers of freight cars during the war were PrJSC «Dniprovagonmash», PJSC «Kryukiv Carriage Building Plant», LLC «DMZ «Karpaty», JSC «Ukrzaliznytsia», the Aurum Group company, and concerning repairsб the company «Lemtrans» should be singled out.

Reparations Withdrawals Of Metallurgical Equipment in Central and Eastern European Countries at Final Stage of Great Patriotic War (1944—1945)

This article is dedicated to the lesser-known aspects of Soviet policy regarding the compulsory seizure of industrial equipment in territories liberated by the Red Army from the fascist bloc states in 1944—1945. Based on an analysis of decrees by the State Defense Committee, the principles of interaction between representatives of industrial People’s Commissariats and military authorities in liberated territories are revealed, with the aim of dismantling and transporting the most promising industrial assets back to the USSR for the needs of restoring the country’s metallurgical complex. The paper provides examples of property disputes among leading economic entities — the industrial People's Commissariats of the USSR — over the right to dismantle industrial facilities for their own benefit. It also sheds light on the activities of Special Assembly Managements under the People’s Commissariat for Construction of the USSR and their authority in the process of seizing industrial assets in territories freed from German control in Eastern Europe. Using the case studies of non-ferrous and ferrous metallurgy enterprises located in territories of fascist bloc countries (Germany, Hungary) liberated by the Red Army, typical approaches to organizing the compulsory dismantling of their equipment are analyzed. The research conducted vividly demonstrates the significance of reparations seizures of industrial equipment in Eastern Europe for the modernization and recovery of the USSR’s metallurgical complex during 1944—1945.