Development of an Energy-Saving Melting Reactor for Energy-Efficient Disposal of Slag Dumps

Arystan Dikhanbaev, Bayandy Dikhanbaev (), Aleksandar Georgiev, Sultan Ybray, Kuat Baubekov, Marat Koshumbayev and Alimzhan Zhangazy
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Arystan Dikhanbaev: Department of Heat and Power Energy, L.N. Gumilyov Eurasian National University, 100 900 Astana, Kazakhstan
Bayandy Dikhanbaev: Department of Heat and Power Energy, Saken Seifullin Kazakh Agrotechnical Research University, 010 011 Astana, Kazakhstan
Aleksandar Georgiev: Institute for Innovation and Smart Technologies, University of Telecommunications and Posts, 1700 Sofia, Bulgaria
Sultan Ybray: Department of Heat and Power Energy, Saken Seifullin Kazakh Agrotechnical Research University, 010 011 Astana, Kazakhstan
Kuat Baubekov: Department of Heat and Power Energy, Saken Seifullin Kazakh Agrotechnical Research University, 010 011 Astana, Kazakhstan
Marat Koshumbayev: Department of Heat and Power Energy, Saken Seifullin Kazakh Agrotechnical Research University, 010 011 Astana, Kazakhstan
Alimzhan Zhangazy: Department of Heat and Power Energy, Saken Seifullin Kazakh Agrotechnical Research University, 010 011 Astana, Kazakhstan

Energies, 2025, vol. 18, issue 10, 1-16

Abstract: Millions of tons of slag and clinker can be found in the dumps of enterprises across the Republic of Kazakhstan. The goal of this project is to create a technology that conserves energy in waste treatment. The novelty of the work is the discovery of a new phenomenon, which shows that in the melt layer, there are two reactions opposite in direction and intensity: slow reactions of the decomposition of complex components into simple molecules and rapid responses of the formation of complex components from simple molecules. The dominance of one of the two reactions affects the process’s fuel consumption. Using this phenomenon, a melting reactor was created, which will reduce specific fuel consumption by 3–4 times compared to a Waelz kiln. It is shown that using a new method of CO 2 decarbonization by zinc, it is possible to ensure the production of zinc sublimates and cast stone products and the full neutralization of CO 2 . The lowest market potential only for Achisai dump clinker would be around USD 125,600,000 if the cost of commercial clinker sublimates is USD 800/t. The expected net profit would be USD 4,466,039/y.

Keywords: slag; clinker; zinc; “ideal” mixing–displacement; casting stone (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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