The development of process-based techno-economic models for the assessment of critical minerals recovery from bitumen extraction tailings

Critical minerals such as zircon and titanium are essential for the development of a low-carbon economy, with increasing demand driven by advancements in renewable energy technologies. Bitumen extraction tailings, specifically from froth treatment operations, represent an underused source of these minerals. This study presents a techno-economic assessment of recovering zircon and titanium from bitumen froth treatment tailings (FTT). The process has two stages: heavy mineral concentration and separation. In the first stage, tailings undergo desliming, flotation, and solvent extraction to concentrate heavy minerals. In the second stage, the concentrate is separated into zircon, rutile, ilmenite, and leucoxene using flotation, gravity, electrostatic, and magnetic techniques. A data-intensive process model was developed to calculate material and energy balances, equipment sizes, capital and operating costs, and internal rate of return (IRR). A plant processing 15.5 million tonnes of tailings annually can recover 157,000 tonnes of heavy minerals, generating an IRR of 9.8% at current market prices for zircon and rutile. Separating the process into two stages results in an IRR of 7.6%, with capacity and zircon price being the most influential factors. Sensitivity analysis shows that the IRR could range from 6.9% to 11.5% depending on input uncertainties. This study provides valuable insights for stakeholders interested in the economic potential of recovering critical minerals from bitumen extraction waste, supporting the circular economy and energy transition goals.