To design industrial reactors, it is important to identify and optimize the effective parameters of the process. Therefore, in this study, a three-level Box–Behnken factorial design was employed combining with a response surface methodology to optimize pulp density, agitation speed and aeration rate in uranium bioleaching in a stirred tank reactor using a pure native culture of Acidithiobacillus ferrooxidans. A mathematical model was then developed by applying the least squares method using the software Minitab Version 16.1.0. The second order model represents the uranium recovery as a function of pulp density, agitation speed and aeration rate. An analysis of variance was carried out to investigate the effects of individual variables and their combined interactive effects on uranium recovery. The results showed that the linear and quadratic terms of variables were statistically significant whilst the interaction terms were statistically insignificant. The model estimated that a maximum uranium extraction (99.99%) could be obtained when the pulp density, agitation speed and aeration rate were set at optimized values of 5.8% w/v, 510 rpm and 250 l/h, respectively. A confirmatory test at the optimum conditions resulted in a uranium recovery of 95%, indicating a marginal error of 4.99%. Furthermore, control tests were performed to demonstrate the effect of A. ferrooxidans in uranium bioleaching process and showed that the addition of this microorganism greatly increases the uranium recovery.
