Techno-economic assessment of bioleaching for metallurgical by-products

• Published in: Journal of environmental management Vol. 358; p. 120904
• Main Authors: Tezyapar Kara, Ipek, Wagland, Stuart T., Coulon, Frederic
• Format: Journal Article
• Language: English
• Published: England Elsevier Ltd 01.05.2024
• Subjects: Acidithiobacillus ferrooxidans; Biohydrometallurgy; Economic feasibility; Secondary resources; Techno-economic assessment; Acidithiobacillus ferrooxidans; Techno-economic assessment; Secondary resources; Economic feasibility; Biohydrometallurgy
• ISSN: 0301-4797; 1095-8630
• DOI: 10.1016/j.jenvman.2024.120904

This study focused on the economic feasibility of two potential industrial-scale bioleaching technologies for metal recovery from specific metallurgical by-products, mainly basic oxygen steelmaking dust (BOS-D) and goethite. The investigation compared two bioleaching scaling technology configurations, including an aerated bioreactor and an aerated and stirred bioreactor across different scenarios. Results indicated that bioleaching using Acidithiobacillus ferrooxidans proved financially viable for copper extraction from goethite, particularly when 5% and 10% pulp densities were used in the aerated bioreactor, and when 10% pulp density was used in the aerated and stirred bioreactor. Notably, a net present value (NPV) of $1,275,499k and an internal rate of return (IRR) of 65% for Cu recovery from goethite were achieved over 20-years after project started using the aerated and stirred bioreactor plant with a capital expenditure (CAPEX) of $119,816,550 and an operational expenditure (OPEX) of $5,896,580/year. It is expected that plant will start to make profit after one year of operation. Aerated and stirred bioreactor plant appeared more reliable alternative compared to the aerated bioreactor plant as the plant consists of 12 reactors which can allow better management and operation in small volume with multiple reactors. Despite the limitations, this techno-economic assessment emphasized the significance of selective metal recovery and plant design, and underscored the major expenses associated with the process. •Technoeconomic assessment of industrial bioleaching for metal extraction.•Acidithiobacillus ferrooxidans bioleaching effective with pulp density up to 10%.•Aerated and stirred bioreactors offer better operation than aerated ones.•Cu recovery from goethite yields a NPV of $1,3M and IRR of 65% over 20 years.•Industrial bioleaching can be profitable for selective metal recovery.