Metal Extraction
Mine to Metal through Hydrometallurgy
Hydrolyz offers end-to-end expertise in developing and optimizing hydrometallurgical processes for the sustainable extraction of critical metals such as copper (Cu), zinc (Zn), gold (Au) and Rare Earth Elements from their primary & secondary sources. Our integrated capabilities span the entire value chain from ore sampling to refined metal production ensuring technical excellence, environmental responsibility, and economic viability.
Hydrometallurgy
Hydrolyz has deep expertise in hydrometallurgy, offering complete solutions for the extraction, recovery, and purification of base and critical metals.
We design and optimize leaching processes including atmospheric, heap, pressure, and bioleaching to maximize metal dissolution. Our capabilities extend to solvent extraction (SX) and electrowinning (EW) for the production of high-purity copper, zinc, and other metals.
Electrometallurgy
Electrometallurgy is increasingly important for the circular economy, enabling energy-efficient and environmentally friendly recovery of metals from low-grade ores, industrial by-products, and electronic waste.
Hydrolyz can provide valuable expertise in developing and optimizing electrowinning and electrorefining processes, from laboratory testing to pilot-scale design, ensuring high recovery rates, impurity control, energy efficiency, and reliable production of pure metals tailored to industrial needs.
Working with Hydrolyz for our copper extraction project exceeded all expectations. Their hydrometallurgical process was robust and efficient. Metal recovery rates soared, and we achieved purity levels we only dreamed of. Responsible, cost-effective, and perfectly aligned with our sustainability goals.
Hydrolyz transformed our waste streams into real value. Using their electrowinning and solvent extraction services, we recovered metals from industrial byproducts that were previously headed to landfill. The environmental benefits and ROI have been impressive. Truly a game changer for our operations.
Partnering with Hydrolyz was the smartest move for our startup. Their technical team guided us from ore sampling through to refined metal, optimizing every step. The pilot scale design they provided gave us confidence in scalability and cost forecasting. We now have a viable path forward in critical metal production.
We wanted a sustainable option for rare earth metals extraction and Hydrolyz delivered. Their circular economy approach, including recovering rare metals from industrial waste and e-waste, reduced our environmental footprint while maintaining high reliability. The support, expertise, and results have made us loyal clients.
Benefits of Working with Hydrolyz
Hydrolyz’s multidisciplinary team combines laboratory-scale experimentation, pilot plant testing, and industrial experience to deliver customized solutions that maximize metal recovery while minimizing environmental footprint. We help our partners move from mine to refined metal with confidence, efficiency, and profitability.
Sampling & Assay
Representative ore and concentrate sampling following ASTM/ISO standards.
Comprehensive chemical assays for accurate grade determination.
Mineralogy & Characterization
Detailed mineralogical studies using XRD, SEM-EDS, optical microscopy, and automated mineralogy (AMICS) to determine ore composition and liberation characteristics.
Size Reduction & Concentration
Crushing, grinding, and milling for optimal particle size distribution.
Gravity, magnetic, and flotation concentration to upgrade feed for downstream processing.
Leaching
Laboratory and pilot-scale leaching for efficient metal dissolution, including atmospheric, heap, and pressure leaching methods.
Acid, alkaline, and bioleaching processes tailored to ore mineralogy.
Solvent Extraction (SX)
Design and optimization of SX circuits for selective recovery and purification of critical Cu, Zn, Ni, and other base metals.
Reagent selection and phase separation efficiency studies.
Electrowinning
EW cell design and operation for high-purity cathode production.
Energy-efficient plating and impurity control strategies.
Flowsheet Development
Comprehensive process flowsheets from raw ore to final metal product.
Incorporation of by-product recovery and waste minimization strategies.
Process Optimization
Parameter optimization for maximum recovery, reagent efficiency, and reduced operating costs.
Integration of process control and automation strategies.
Economic Analysis
Capital and operating cost estimation.
Feasibility assessments and return-on-investment (ROI) projections.
Current Projects
Sustainable Copper Extraction from Sulfide Ore via Hydrometallurgical Route
Our project focuses on developing an innovative hydrometallurgical process for copper extraction from sulfide ores, addressing both efficiency and sustainability challenges. Traditional pyrometallurgical routes are energy-intensive and environmentally taxing, while conventional hydrometallurgical approaches often suffer from slow leaching kinetics. To overcome these barriers, we have designed a process with an accelerated leaching rate using sustainable lixiviants, minimizing environmental impact while ensuring high copper recovery.
The process flow includes:
Sustainable Leaching: Enhanced leaching kinetics for rapid dissolution of copper from sulfide ores under controlled conditions.
Solid-Liquid Separation: Efficient clarification and filtration systems to ensure clean pregnant leach solution (PLS) for downstream processing.
Impurity Removal: Selective precipitation and treatment steps to eliminate dissolved iron, aluminum, manganese, and other contaminants.
Solvent Extraction (SX): High selectivity for copper recovery from PLS, producing a purified electrolyte.
Electrowinning (EW): Deposition of high-purity copper cathodes with consistent quality.
We are currently designing a pilot plant with the capability to produce 1 kg of copper cathode per day, serving as a proof-of-concept for scalability. This modular pilot setup will enable optimization of leaching parameters, impurity removal strategies, and SX/EW operating conditions, providing critical data for commercial adoption.
The technology is now ready to be adopted by industry, offering a low-carbon, eco-friendly, and economically viable alternative to conventional copper extraction. By utilizing indigenous resources and reducing dependence on imports, this project supports the circular economy and strengthens national resource security.
Zinc Recovery Form Electric Arc Furnace Flue Dust
We are currently designing and constructing a pilot plant for the recovery of zinc from Electric Arc Furnace (EAF) flue dust, a hazardous steelmaking byproduct rich in zinc and other valuable metals. The pilot facility is being engineered to produce 1 kg of refined zinc per day, demonstrating the scalability and industrial feasibility of our process.
The technology follows a simple and sustainable hydrometallurgical route, involving:
Dust Preparation & Leaching: Dissolution of zinc values under controlled conditions.
Solid–Liquid Separation: Removal of undissolved residues for a clean pregnant leach solution.
Impurity Removal: Elimination of dissolved iron, manganese, and other contaminants to ensure product quality.
Solvent Extraction & Electrowinning (SX/EW): Production of high-purity refined zinc cathodes.
This indigenous solution not only offers a safe and eco-friendly alternative to the current practice of landfilling EAF dust but also contributes directly to the circular economy, reducing import dependence and unlocking a new domestic supply of refined zinc. The pilot project will serve as a foundation for full-scale adoption by the steel and non-ferrous industries in Pakistan.
Gold Extraction From E-Waste via Aqueous Processing
Electronic waste (e-waste) is one of the fastest-growing waste streams worldwide, containing significant quantities of valuable precious metals, particularly gold, along with copper, silver, palladium, and other strategic materials. Conventional disposal practices not only waste these resources but also release toxic substances into the environment.
Our project focuses on an aqueous processing route for the efficient extraction and recovery of gold from e-waste. The process is designed to achieve high recovery rates of gold while being environmentally responsible.
The process includes:
Pre-Processing & Liberation: Mechanical and chemical methods to liberate metal fractions from printed circuit boards and other e-waste components.
Sustainable Leaching: Use of advanced aqueous lixiviants that selectively dissolve gold with minimal environmental impact.
Solid–Liquid Separation: Clean separation of leach residues for further treatment or safe disposal.
Precious Metal Recovery: Efficient recovery of gold through selective precipitation, solvent extraction, or electro-winning, yielding high-purity product.
This technology demonstrates a circular economy pathway, converting discarded electronics into a valuable resource stream. By enabling local recovery of gold at high efficiency, the process reduces reliance on imported precious metals, minimizes environmental burden, and creates opportunities for green jobs in the recycling sector.
Recovery of Rare Earth Metals From Industrial Waste Streams
Industrial wastes such as red mud, coal fly ash, phosphogypsum, and metallurgical residues contain significant amounts of rare earth elements (REEs) like neodymium, dysprosium, cerium, lanthanum, and yttrium, which are critical for clean energy and advanced technologies. Recovering these metals through hydrometallurgical and selective separation techniques not only mitigates environmental hazards but also establishes a sustainable and cost-effective domestic supply chain. By turning waste into value, this approach strengthens the circular economy and supports high-demand industries such as permanent magnets, batteries, catalysts, and renewable energy systems. Contact us for further information!
About Hydrolyz
Hydrolyz is a specialized technology company providing end-to-end hydrometallurgical solutions—from mine to refined metal—through innovative, efficient, and sustainable process development.