Unlocking hidden value in fine incinerator bottom ash (IBA): a new pilot processing plant

Incinerator bottom ash (IBA) from waste-to-energy facilities contains significant quantities of valuable heavy metals, such as copper, gold, and silver. Interest in recovering these materials continues to grow, driven by rising commodity prices, increasingly strict environmental regulations, and governmental incentives to recover more waste materials for re-use.

Today, these heavy metals are commonly recovered from IBA if particles sizes are above 2 mm. However, the fine fraction (0–2 mm) also contains substantial value. Recovering metals from this size range at an industrial level remains challenging – despite promising laboratory results.

From lab success to industrial feasibility

Laboratory tests have demonstrated good potential for recovering metals from particles smaller than 2 mm. Yet, these small‑scale tests often lack the representativeness needed to build a solid business case for a full‑scale industrial installation.

To bridge this gap, IHC Mining partnered with Urban Metals to develop a pilot processing plant, designed specifically to transition fine‑fraction recovery from laboratory proof‑of‑concept to industrial reality.

This pilot plant addresses three key limitations of laboratory test work:

• Prolonged test periods, reducing the impact of fluctuations in IBA composition
• Large bulk sample processing, improving accuracy and eliminating analytical errors
• A fully representative flowsheet, mirroring industrial‑scale process conditions

Pilot processing plant operation to support full‑scale business cases

IHC Mining and Urban Metals jointly developed a state‑of‑the‑art pilot plant for the recovery of fine heavy non‑ferrous metals (HNF) from incinerator bottom ash.

The pilot facility can be rented by IBA processors, enabling them to:

• Assess metal recoveries over longer, realistic operational periods
• Validate process routes before committing to full‑scale investment
• Produce a high‑grade HNF concentrate suitable for direct sale to smelters
• Build a reliable, data‑driven business case in terms of recovery and grade for industrial implementation

Construction of the pilot plant has started, with full operational capability scheduled by the end of May.

If you would like to learn more about the pilot plant, or if you need support in developing an optimised processing flowsheet, please don’t hesitate to contact us.