Bioengineered Microbes Boost Copper Recovery From Waste Ore

New extraction tech recovers more copper from low-grade sulfide ores

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A new microbial-based approach to copper recovery is showing real potential to unlock value from low-grade ores that were previously uneconomical to mine. Developed by Colorado-based startup Endolith, the technology has been tested in collaboration with BHP’s innovation unit, Think & Act Differently (TAD), using ore samples with under 1% copper content from chalcopyrite and pyrite.

Field-simulated column tests using site-matched fluids and materials revealed faster and more complete copper recovery than standard heap leaching processes. Performance was consistent across a range of temperatures—from 30°C to 65°C—indicating the system’s robustness across varied operating conditions. This method stands out for its ability to address the inefficiencies traditionally associated with extracting copper from primary sulfide ores.

Endolith’s system leverages engineered microbes to drive the breakdown and release of copper, moving away from the chemical-heavy approaches that dominate current leaching techniques. With copper increasingly central to electrification and clean energy infrastructure, this represents a potential shift in how the industry treats low-grade material.

Demand Pressures Highlight Need for Alternative Extraction Methods

The timing of this innovation lines up with significant pressure on the global copper supply chain. Average copper ore grades have dropped by around 40% since 1991, and industry projections show global copper demand hitting 50 million metric tonnes annually by 2035—driven in part by clean energy and electric vehicle growth.

More than 70% of the world’s copper reserves are found in ores considered too complex or low-grade to process economically with conventional methods. As capital expenditures rise and environmental scrutiny increases, new extraction pathways are needed.

Endolith’s solution integrates into existing infrastructure, allowing operators to improve yields without major process overhauls. By reducing the need for toxic leaching chemicals, the system may also ease environmental permitting concerns. The platform's potential to make stranded or underutilized resources economically viable could change how the sector approaches mine planning and asset recovery.

With copper prices forecast to rise by 20% by 2027 and investment in raw materials estimated at $2.1 trillion by 2050, solutions like this may be key to bridging the supply-demand gap in the near term.

Environment + Energy Leader