Statistically based experimental designs were applied to screen and optimize the bioleaching of spent hydrocracking catalyst by Penicillium simplicissimum. Eleven factors were examined for their significance on bioleaching using a Plackett-Burman factorial design. Four significant variables (pulp density, sucrose, NaNO(3), and yeast extract concentrations) were selected for the optimization studies. The combined effect of these variables on metal bioleaching was studied using a central composite design (CCD). Second-order polynomials were established to identify the relationship between the recovery percent of the metals and the four significant variables. The optimal values of the variables for maximum metals bioleaching were as follows: pulp density (4.0%, w/v), sucrose (90 g/L), NaNO(3) (2 g/L) and yeast extract (0.36 g/L). The maximum metals recovery percentages from the predicted models were 97.6% Mo, 45.7% Ni, and 14.3% Al. These values were in perfect agreement with the actual experimental values, which were (98.8 +/- 0.9)% Mo, (46.5 +/- 0.6)% Ni, and (13.7 +/- 0.4)% Al. The growth kinetics of the fungus in the presence of the spent catalyst at various pulp densities (2-11%) and optimal condition was modeled using the modified Gompertz model. The kinetic parameters in the system were estimated using MATLAB R2008a. Results showed that the modified Gompertz model fit the experimental data well. The relationship between the specific growth rate and pulp density was found by modifying the Luong inhibition model which gave maximum specific growth rate of 0.034 day(-1), optimal pulp density of 3.95% w/v and critical inhibitor concentration of 10.9% w/v. (C) 2011 Elsevier B.V. All rights reserved.