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The development of cost-effective and green recycling technologies for secondary metal recovery from industrial wastes is one of the new challenges on the sustainable development agenda. By incorporating cost and resource efficiency assessment into the technology innovation process, we aim to improve the sustainability of new recycling technologies by minimizing process waste, improving resource efficiency, thus reducing the recovery process cost. This paper focuses on modeling and assessing the production cost and resource use efficiency for closed-loop nickel recovery from spent hydrogenation catalysts. The engineering economics factors and process variables that affect the profitability and resource efficiency of nickel recovery are identified. They are modeled in cost and efficiency metrics. Model-based scenarios assessment revealed that compared to open-loop nickel recovery, the closed-loop concept delivers more cost-effective and greener recycling solutions. The closed-loop process cost reduction via efficient resource use and process waste minimization is in the range of 18.4% to 24.0% compared to the open-loop process option.

This paper investigates the economic viability of a closed-loop process for nickel recovery from roasted catalytic wastes. The effects of process parameters and market factors that drive the bottom-line profitability of nickel recovery are identified and analyzed using a cost and revenue evaluation model developed in the study. The main factors include the production batch size, material cost, and nickel selling price. With a nickel market value higher than S$18.85 per kg, the process is economically viable even with a batch size as small as 50 kg/batch. Given that the current nickel selling price at the metal exchange market has reached around S$24-28/kg, the economic feasibility of the process is confirmed.