Proposal and analysis of a comprehensive framework for energy harvesting from process water flow in the Sungun copper complex

• Prioritizing efficiency & waste recovery over new energy sources in mining sector. • Tackling Iran’s electricity limits with decentralized recovery in remote mines. • Techno-economic optimization ensures real-world deployment of recovery systems. • Bridging theory & practice to enable sustainable energy in resource-heavy industries In the current energy landscape, optimizing energy efficiency and recovering waste energy have become more critical than developing new energy resources. Energy recovery from process water flow in large-scale mines is a research gap in the field of fluid-based energy recovery, which is addressed in this study. Accordingly, this research investigates energy recovery from a major mining complex in Iran. This issue becomes even more critical given that Iran faces severe challenges in supplying electrical energy, and the aforementioned mining complex is located in a remote mountainous area, requiring a decentralized generation system. This paper evaluates the energy harvesting potential from high-head process water pipelines (2 × 4 km, 16-inch diameter) at the Sungun copper mine. With a sustained flow rate of 870 m³/h and a geometric head of 210 m, the system offers a viable opportunity for hydro-based energy recovery. Thus, an energy recovery system has been proposed, incorporating hydrodynamic/mechanical design, uncertainty analysis, and economic assessment. Results indicate 712 kW of recoverable power from currently unused process water flow, with economic analysis showing an attractive 1.3-year payback period for the hydroelectric system. The study quantitatively assessed critical electromechanical equipment efficiencies used in the designed system to develop an implementation-ready framework that bridges theoretical models with operational requirements for practical system realization. The study quantitatively evaluated how current water supply pipeline materials affect energy recovery efficiency, with detailed performance metrics provided for each material category. The analysis reveals polyethylene piping systems yield 22% greater power generation than riveted steel alternatives.