The article addresses the problem of accumulation of high-chromium (up to 12%) sludges at the Aktobe Ferroalloy Plant, which creates environmental and production risks. As a solution, the processing of sludges using the KPFSH-50 jigging complex is proposed to obtain a metal concentrate containing at least 40% chromium. Experimental-industrial tests (EIT) on smelting of high-carbon ferrochrome metal concentrate (MFC) were carried out in smelting shop No. 1 on furnace No. 39. During the tests, 398 tons of MFC were smelted, resulting in 223.26 tons of commercial high-carbon ferrochrome (HCFeCr), with chromium recovery into metal exceeding 92%. Material balances of the smelting process for different initial chromium contents in MFC are presented, along with key technological indicators, including specific consumption of electric energy, electrodes, refractories, raw materials, and auxiliary materials. Data analysis revealed reserves for improving process efficiency through reduction of furnace downtime and power losses. The results confirm the feasibility of industrial implementation of sludge recycling technology, contributing to environmental and economic optimization of production.

BISENBIN M.A.

Master’s degree student, K. Zhubanov Aktobe regional university, Aktobe, Kazakhstan

E-mail: Malik.Bisenbin@erg.kz, https://orcid.org/0009-0007-1706-7542

SHABANOV E.ZH.

PhD, associate professor, K. Zhubanov Aktobe regional university, Aktobe, Kazakhstan

E-mail: yshabanov@zhubanov.edu.kz, https://orcid.org/0000-0001-6902-1211

ZHUMAGALIEV E.U.

Candidate of technical sciences, associate professor, K. Zhubanov Aktobe regional university, Aktobe, Kazakhstan

E-mail: yzhumagaliyev@zhubanov.edu.kz, https://orcid.org/0000-0003-2227-0661

URAZGALIYEVA A.N.

Laboratory assistant, K. Zhubanov Aktobe regional university, Aktobe, Kazakhstan

E-mail: a.urazgaliyeva@zhubanov.edu.kz, https://orcid.org/0009-0008-2989-9327

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high-carbon ferrochrome, metal concentrate, sludges, smelting, waste, recycling