Economic considerations in the application of bioleaching for metal extraction from solid matrices

This study employed the SuperPro Designer software to evaluate how various operational and commercial parameters influence both operating and capital costs in metal bioleaching processes using stirred tank reactors for solid matrices. A baseline scenario was defined, consisting of a bioleaching stage in a continuous stirred tank reactor (CSTR) with a hydraulic retention time of 48 h and a pulp density of 10% ( w /w). The bioreactor temperature was maintained at 40 °C using natural gas heating. For a processing capacity of 1000 kg of solids per hour, the estimated capital cost was $ US 42.540 million. Annual operating costs for this configuration were calculated at $ US 11.773 million, corresponding to $ US 1.402 per kilogram of solids processed. The economic impact of variations in 19 different parameters was analyzed. The results show that operating costs are strongly influenced by solids concentration (pulp density) and hydraulic retention time, followed by processing capacity, aeration rate, added nutrient concentration, and CO₂-enriched air injection. • An economic study was conducted using SuperPro Designer software. • This study focused on a reference scenario for bioleaching of metals. • The scenario is based on a bioleaching stage using ferrous sulfate and elemental sulfur. • A sensitivity study was conducted on 19 operating and market parameters.