Nitric Acid Leaching for Magnesium Extraction from Asbestos Ore Waste: From DoE to Predictive Modeling and Cost-Efficient Optimization

Kazakhstan's asbestos industry produces over 3 million tons of waste annually. The primary component of asbestos ore waste (AOW) is magnesium rich minerals. In this study, the extraction of magnesium from AOW with nitric acid (HNO₃) was for the first time systematically studied. A series of experiments were conducted to optimize acid concentration (300-600 g/L), leaching temperature (55-95 °C), leaching time (60-180 min), solid-to-liquid ratio (1:3-1:7), and particle size, with the overall goal of maximizing magnesium extraction and cost efficiency. Our results provide dependence of magnesium extraction in the order of acid concentration > temperature > time > solid-to-liquid ratio, while particle size was found to be negligible. The cost-efficiency optimization demonstrated the positive impact of the relatively low acid concentrations (< 450 g/L) and temperatures between 65 and 85 °C, while the Protodyakonov model validated a linear dependence of the extraction rate on temperature and acid concentration. Our model demonstrates that extraction efficiencies of up to 90% can be achieved while reducing reagent use and lowering the overall cost of magnesium production. Leaching of magnesium by HNO₃ also opens a pathway to a closed-cycle process, due to the formation of magnesium nitrate. The thermal decomposition of Mg(NO₃)₂ provides valuable products such as MgO and NO₂ reused in HNO₃ regeneration for subsequent cycles. The proposed model predicts magnesium extraction from asbestos ore depending on leaching parameters with reasonable accuracy.