A Bioleaching Process for Sustainable Recycling of Complex Structures with Multi-Metal Layers

Industrial waste is accumulating, while primary metal resources are depleting. Bioleaching has been shown to be a cost-effective and environmentally friendly approach to metal recovery from waste, but improved designs are needed for large-scale recycling. Metal components that are manufactured by electrodeposition over a mandrel can be difficult to recycle using conventional techniques due to their complex geometry and inner Ag coating. A sustainable biotechnology for separating Cu and Ag from waste electrodeposited components is presented. Two-step bioleaching experiments were performed, during which Cu was solubilized by Fe³⁺ regenerated by Acidithiobacillus (At.) ferrooxidans CF3 and a consortium of ten acidophilic Fe²⁺-oxidizers. High Cu recovery rates were achieved in agitated flasks (22 ◦C, pH 1.9), with At. ferrooxidans solubilizing 94.7% Cu in 78 days and the consortium 99.2% Cu in 59 days. Copper bio-solubilization was significantly accelerated in a laboratory-scale bioreactor (32 ◦C, 1 L air min⁻¹) using the bacterial consortium adapted to elevated Cu concentrations, reaching >99.6% Cu extraction in only 12 days. The bioreactor was dominated by Leptospirillum and Acidithiobacillus, with their proportions changing (from 83.2 to 59% of total reads and from 3.6 to 29.4%, respectively) during the leaching process. Dissolved Cu was recovered from the bioleachates (containing 14 to 22 g Cu L⁻¹) using electrowinning; >99% of the Cu was deposited (with Cu purity of 98.5 to 99.9%) in 3.33 h (at current efficiency between 80 and 92%). The findings emphasize the importance of a bioleaching system design to achieve economical separation of base and precious metals from industrial wastes. The presented technology minimizes waste generation and energy consumption. On a larger scale, it has the potential to contribute to the development of industrial recycling processes that will protect natural resources and contribute to the Net Zero target.