Effect of Production Conditions on Composition and Properties of Phosphating Solutions Based on Kazakhstan Ore Dressing Wastes
Kubekova S.N. Raimbekova A.S. Kapralova V.I. Dalbanbay A. Kuli Zn. Kuznetsov V.E. Varol E.A.
December 2025Engineered Science Publisher
ES Materials and Manufacturing
2025#30
The material and phase composition of manganese ore–processing waste from the Altyn-Shoko deposit were comprehensively analyzed, and the optimal conditions for producing phosphating solutions from this technogenic material were established. Phosphate coatings formed on St3 carbon steel using these synthesized solutions were evaluated using gravimetric corrosion tests, electrochemical measurements, and Scanning Electron Microscopy (SEM) – Energy-Dispersive X-ray Spectroscopy (EDS) analyses. Mechanical activation of the waste, intended to break down mineral aggregates, increased the phosphoric acid leaching efficiency at 25 °C from 66.9% to 72.9% but simultaneously reduced the free H3PO4 content in the solution. Although this treatment improved dissolution, it also accelerated sludge formation during phosphating and decreased the corrosion resistance of the resulting coatings. In contrast, phosphating solutions prepared from non-activated waste produced uniform, dense, and compact phosphate layers composed of iron, calcium, manganese, and phosphorus compounds, yielding superior protective performance. Coatings derived from mechanically activated waste were more porous and consisted mainly of iron–calcium–phosphate phases, which correlated with their reduced barrier properties. Overall, the results demonstrate the potential of Altyn-Shoko beneficiation waste as a sustainable feedstock for low-cost phosphating solutions while highlighting the limitations introduced by mechanical activation.
Beneficiation waste , Corrosion protection , Phosphate coatings , Phosphating process , Phosphating solutions
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Kazakh National Research Technical University named after K.I. Satbayev, Satbayev University, Almaty, 050013, Kazakhstan
Eskisehir Technical University, Faculty of Engineering, Department of Chemical Engineering, Eskişehir, 26555, Turkey
Kazakh National Research Technical University named after K.I. Satbayev
Eskisehir Technical University
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