Biohydrometallurgical technology of a complex copper concentrate process

Leaching of sulfide-oxidized copper concentrate of the Udokan deposit ore with a copper content of 37.4% was studied. In the course of treatment in a sulfuric acid solution with pH 1.2, a copper leaching rate was 6.9 g/kg h for 22 h, which allowed extraction of 40.6% of copper. As a result of subsequent chemical leaching at 80 degrees C during 7 h with a solution of sulphate ferric iron obtained after bio-oxidation by an association of microorganisms, the rate of copper recovery was 52.7 g/kg h. The total copper recovery was 94.5% (over 29 h). Regeneration of the Fe3+ ions was carried out by an association of moderately thermophilic microorganisms, including bacteria of genus Sulfobacillus and archaea of genus Ferroplasma acidiphilum, at 1.0 g/l h at 40 degrees C in the presence of 3% solids obtained by chemical leaching of copper concentrate. A technological scheme of a complex copper concentrate process with the use of bacterial-chemical leaching is proposed.     

Chemical and biological leaching of enargite

Enargite (Cu 3 AsS 4 ) was leached faster by bacteria in sulfuric acid medium (pH 1.6) with added ferric sulfate than by chemical leaching at the same or higher iron concentration. During chemical leaching with ferric iron, the copper dissolution rate decreased from an initial value of 0.03% per hour to a value of 0.002% per hour. Enargite is oxidized to elemental sulfur and dissolved arsenic (As 3+ and As 5+ ). Less than 10% of sulfur is oxidized to sulfate. The arsenic and copper dissolutions observed in bacterial leaching experiments suggest the existence of a specific bacterial action on the leaching of enargite, demonstrated by the ability of bacteria to oxidize enargite at very low concentration of dissolved iron and by the higher dissolution rate obtained in bacterial leaching compared to chemical ferric leaching.     

Leaching of nonferrous metals from copper converter slag with application of acidophilic microorganisms

The leaching process of copper and zinc from copper converter slag with ferric iron in sulfuric acid solutions obtained using the association of acidophilic chemolithotrophic microorganisms was investigated. The best parameters of chemical leaching (temperature 70°C, an initial concentration of ferric iron in the leaching solution of 10.1 g/L, and a solid phase content in the pulp of 10%) were selected. Carrying out the process under these parameters resulted in the recovery of 89.4% of copper and 39.3% of zinc into the solution. The possibility of the bioregeneration of ferric iron in the solution obtained after the chemical leaching of slag by iron-oxidizing acidophilic chemolithotrophic microorganisms without inhibiting their activity was demonstrated.     

Microbial leaching of metals from sulfide minerals

Microorganisms are important in metal recovery from ores, particularly sulfide ores. Copper, zinc, gold, etc. can be recovered from sulfide ores by microbial leaching. Mineral solubilization is achieved both by 'direct (contact) leaching' by bacteria and by 'indirect leaching' by ferric iron (Fe(3+)) that is regenerated from ferrous iron (Fe(2+)) by bacterial oxidation. Thiobacillus ferrooxidans is the most studied organism in microbial leaching, but other iron- or sulfide/sulfur-oxidizing bacteria as well as archaea are potential microbial agents for metal leaching at high temperature or low pH environment. Oxidation of iron or sulfur can be selectively controlled leading to solubilization of desired metals leaving undesired metals (e.g., Fe) behind. Microbial contribution is obvious even in electrochemistry of galvanic interactions between minerals.     

Mineral and iron oxidation at low temperatures by pure and mixed cultures of acidophilic microorganisms

An enrichment culture from a boreal sulfide mine environment containing a low-grade polymetallic ore was tested in column bioreactors for simulation of low temperature heap leaching. PCR-denaturing gradient gel electrophoresis and 16S rRNA gene sequencing revealed the enrichment culture contained an Acidithiobacillus ferrooxidans strain with high 16S rRNA gene similarity to the psychrotolerant strain SS3 and a mesophilic Leptospirillum ferrooxidans strain. As the mixed culture contained a strain that was within a clade with SS3, we used the SS3 pure culture to compare leaching rates with the At. ferrooxidans type strain in stirred tank reactors for mineral sulfide dissolution at various temperatures. The psychrotolerant strain SS3 catalyzed pyrite, pyrite/arsenopyrite, and chalcopyrite concentrate leaching. The rates were lower at 5 degrees C than at 30 degrees C, despite that all the available iron was in the oxidized form in the presence of At. ferrooxidans SS3. This suggests that although efficient At. ferrooxidans SS3 mediated biological oxidation of ferrous iron occurred, chemical oxidation of the sulfide minerals by ferric iron was rate limiting. In the column reactors, the leaching rates were much less affected by low temperatures than in the stirred tank reactors. A factor for the relatively high rates of mineral oxidation at 7 degrees C is that ferric iron remained in the soluble phase whereas, at 21 degrees C the ferric iron precipitated. Temperature gradient analysis of ferrous iron oxidation by this enrichment culture demonstrated two temperature optima for ferrous iron oxidation and that the mixed culture was capable of ferrous iron oxidation at 5 degrees C.     

Leaching of iron and toxic heavy metals from anaerobically-digested sewage sludge

Summary Heavy metal-loaded sewage sludge was leached abiotically using FeCl₂ and FeCl₃ which are applied in waste water treatment plants to eliminate phosphate and for coagulation. Due to the hydrolyzing nature of ferric iron, ferric chloride (100 mmll L^–1) was able to solubilize more than 90% of copper and zinc and more than 80% of cadmium, with an optimal pulp density of 3% (w/v), after 10 h of exposition at 25°C. Chromium, lead and nickel were solubilized to an extent of 40–70%. With the exception of copper (redoxolysis), all heavy metals monitored were leached following the principle of acidolysis. Chemical leaching with iron resulted in a secondary contamination of sewage sludge (96 g iron per kg dry weight). The insoluble iron compounds which were precipitated for adsorbed to sludge flocks could be resolubilized with oxalic acid (100 mM, pH<3.3) up to an extent of 90%. Iron was leached by acidolysis and held in solution by complexation with oxalic acid. The pH optimum for the treatment of sewage sludge with 100 mmol L^–1 oxalic acid was pH 3.3. At this pH an excessive solubilization of nutrient elements and compounds (phosphorus, nitrogen, alkali and alkali earth elements) could be avoided concomitantly leaching 75% iron. Furthermore the hydrophobicity of the sewage sludge was significantly reduced as a result of treatment with iron chloride.Thiobacillus ferrooxidans (isolated from arsenopyrite and adapted on sewage sludge) utilized ferrous iron as an energy source in the presence of chloride ions (FeCl₂) as efficiently as ferrous sulphate. No toxic effects of oxalic acid onT. ferrooxidans were observed at the prevailing concentration.     

Biohydrometallurgical technology of copper recovery from a complex copper concentrate

Leaching of sulfide-oxidized copper concentrate of the Udokan deposit ore with a copper content of 37.4% was studied. In the course of treatment in a sulfuric acid solution with pH 1.2, a copper leaching rate was 6.9 g/kg h for 22 hours, which allowed extraction of 40.6% of copper. At subsequent chemical leaching at 80°C during 7 hours with a solution of ferric sulfate obtained after biooxidation by an association of micro-organisms, the rate of copper recovery was 52.7 g/kg h. The total copper recovery was 94.5% (over 29 hours). Regeneration of the Fe³⁺ ions was carried out by an association of moderately thermophilic microorganisms, including bacteria of genus Sulfobacillus and archaea Ferroplasma acidiphilum, at 1.0 g/L h at 40°C in the presence of 3% solids obtained by chemical leaching of copper concentrate. A flowsheet scheme of a complex copper concentrate process with the use of bacterial-chemical leaching is proposed.     

Microbiological leaching of zinc and lead ores of the Tekeli deposit

In certain regions of the West Tekeli lead-zinc ore deposti, the number of Thiobacillus ferrooxidans cells reaches 10(6) per 1 ml of ore water. Spontaneous bacterial leaching of sulphide ore is confirmed by an increase in the concentration of ferric iron and zinc in ore water. As a result of this leaching, up to 40 per cent of zinc and 60 per cent of lead have been leached from lead-zinc ore within 271-286 days. Bacterial leaching of lead intermediate products has shown that the maximum rate of galenite oxidation is reached at 50--65 degrees C and the content of Fe3+ in a solvent being above 20 g per litre. Microbiological leaching can be used for selective extraction of zinc and lead. Zinc dissolves directly in the leaching bacterial solution while lead remains in the precipitate and is then dissolved under the action of concentrated NaCl solutions.     

Kinetics of iron oxidation by Leptospirillum ferriphilum dominated culture at pH below one

The kinetics of ferrous iron oxidation by Leptospirillum ferriphilum (L. ferriphilum) dominated culture was studied in the concentration range of 0.1-20 g Fe(2+)/L and the effect of ferric iron (0-60 g Fe(3+)/L) on Fe(2+) oxidation was investigated at pH below one. Denaturing gradient gel electrophoresis of PCR amplified 16S rRNA genes followed by partial sequencing confirmed that the bacterial community was dominated by L. ferriphilum. In batch assays, Fe(2+) oxidation started without lag phase and the oxidation was completed within 1 to 60 h depending on the initial Fe(2+) concentration. The specific Fe(2+) oxidation rates increased up to around 4 g/L and started to decrease at above 4 g/L. This implies substrate inhibition of Fe(2+) oxidation at higher concentrations. Haldane equation fitted the experimental data reasonably well (R(2) = 0.90). The maximum specific oxidation rate (q(m)) was 2.4 mg/mg VS . h, and the values of the half saturation (K(s)) and self inhibition constants (K(i)) were 413 and 8,650 mg/L, respectively. Fe(2+) oxidation was competitively inhibited by Fe(3+) and the competitive inhibition constant (K(ii)) was 830 mg/L. The time required to reach threshold Fe(2+) concentration was around 1 day and 2.3 days with initial Fe(3+) concentration of 5 and 60 g/L, respectively. The threshold Fe(2+) concentration, below which no further Fe(2+) oxidation occurred, linearly increased with increasing initial Fe(2+) and Fe(3+) concentrations. Fe(2+) oxidation proceeds by L. ferriphilum dominated culture at pH below 1 even in the presence of 60 g Fe(3+)/L. This indicates potential of using and biologically regenerating concentrated Fe(3+) sulfate solutions required, for example, in indirect tank leaching of ore concentrates.     

The effect of temperature on the continuous ferrous-iron oxidation kinetics of a predominantly Leptospirillum ferrooxidans culture.

The ferrous-iron oxidation kinetics of a bacterial culture consisting predominantly of Leptospirillum ferrooxidans were studied in continuous-flow bioreactors. The bacterial culture was fed with a salts solution containing 12 g/L ferrous-iron, at dilution rates ranging from 0.01 to 0.06 l/h, and temperatures ranging from 30 to 40 degrees C, at a pH of 1.75. The growth rate, and the oxygen and ferrous-iron utilization rates of the bacteria, were monitored by means of off-gas analysis and redox-potential measurement. The degree-of-reduction balance was used to compare the theoretical and experimental values of r(CO(2)), -r(O(2)) and -r(Fe(+2)), and the correlation found to be good. The maximum bacterial yield on ferrous-iron and the maintenance coefficient on ferrous-iron, were determined using the Pirt equation. An increase in the temperature from 30 to 40 degrees C did not appear to have an effect on either the maximum yield or maintenance coefficient on ferrous-iron. The average maximum bacterial yield and maintenance coefficient on ferrous-iron were found to be 0.0059 mmol C/mmol Fe(2+) and 0.7970 mmol Fe(2+)/mmol C)/h, respectively. The maximum specific growth rate was found to be 0.077 l/h. The maximum specific ferrous-iron utilization rate increased from 8.65 to 13.58 mmol Fe(2+)/mmol C/h across the range from 30 to 40 degrees C, and could be described using the Arrhenius equation. The kinetic constant in bacterial ferrous-iron oxidation increased linearly with increasing temperature. The ferrous-iron kinetics could be accurately described in terms of the ferric/ferrous-iron ratio by means of a Michaelis-Menten-based model modified to account for the effect of temperature. A threshold ferrous-iron level, below which no further ferrous-iron utilization occurred, was found at a ferric/ferrous-iron ratio of about 2500. At an overall iron concentration of 12 g/L, this value corresponds to a threshold ferrous-iron concentration of 78.5 x10(-3) mM.     

Arsenic precipitation in the bioleaching of enargite by Sulfolobus BC at 70 °C

Enargite (Cu₃AsS₄) was leached at 70°C by Sulfolobus BC in shake-flasks. The highest copper dissolution (52% after 550 h of leaching) was obtained with bacteria and 1 g l^–1 ferric ion. In the absence of ferric ion, Sulfolobus BC catalyzes the bioleaching of enargite through a direct mechanism after adhesion onto the mineral surface. In ferric bioleaching, arsenic precipitated as ferric arsenate and arsenic remained associated to the solid residues, preventing the presence of a high dissolved arsenic concentration in the leaching solution. About 90% inhibition of bacterial growth rate and activity was observed for dissolved arsenic concentrations above 600 mg l^–1 for As(III) and above 1000 mg l^–1 for As(V). Arsenic-bearing copper ores and concentrates could be leached by Sulfolobus BC in the presence of ferric iron due to the favourable precipitation of arsenic ion as ferric arsenate, avoiding significant bacterial inhibition.     

Microbiological Leaching of Metallic Sulfides

The percentage of chalcopyrite leached in percolators by Thiobacillus ferrooxidans was dependent on the surface area of the ore but not on the amount. Typical examples of ore leaching, which demonstrate the role of the bacteria, are presented. In stationary fermentations, changes in KH(2)PO(4) concentration above or below 0.1% decreased copper leaching as did reduction in the MgSO(4).7H(2)O and increase in the (NH(4))(2)SO(4) concentration. Bacterial leaching of chalcopyrite was more effective than nonbiological leaching with ferric sulfate; ferric sulfate appeared to retard biological leaching, but this effect was likely caused by formation of an insoluble copper-iron complex. Ferrous sulfate and sodium chloride singly accentuated both bacterial and nonbiological leaching of chalcocite but jointly depressed bacterial action. Sodium chloride appeared to block bacterial iron oxidation without interfering with sulfide oxidation. Bacterial leaching of millerite, bornite, and chalcocite was greatest at pH 2.5. The economics of leaching a number of British Columbia ore bodies was discussed.     

Effects of medium and trace metals on kinetics of carbon tetrachloride transformation by Pseudomonas sp. strain KC.

Under denitrifying conditions, Pseudomonas sp. strain KC transforms carbon tetrachloride (CT) to carbon dioxide via a complex but as yet undetermined mechanism. Transformation rates were first order with respect to CT concentration over the CT concentration range examined (0 to 100 micrograms/liter) and proportional to protein concentration, giving pseudo-second-order kinetics overall. Addition of ferric iron (1 to 20 microM) to an actively transforming culture inhibited CT transformation, and the degree of inhibition increased with increasing iron concentration. By removing iron from the trace metals solution or by removing iron-containing precipitate from the growth medium, higher second-order rate coefficients were obtained. Copper also plays a role in CT transformation. Copper was toxic at neutral pH. By adjusting the medium pH to 8.2, soluble iron and copper levels decreased as a precipitate formed, and CT transformation rates increased. However, cultures grown at high pH without any added trace copper (1 microM) exhibited slower growth rates and greatly reduced rates of CT transformation, indicating that copper is required for CT transformation. The use of pH adjustment to decrease iron solubility, to avoid copper toxicity, and to provide a selective advantage for strain KC was evaluated by using soil slurries and groundwater containing high levels of iron. In samples adjusted to pH 8.2 and inoculated with strain KC, CT disappeared rapidly in the absence or presence of acetate or nitrate supplements. CT did not disappear in pH-adjusted controls that were not inoculated with strain KC.     

A mathematical model for the bacterial oxidation of a sulfide ore concentrate

The effect of dilution rate and feed solids concentration on the bacterial leaching of a pyrite/arsenopyrite ore concentrate was studied. A mathematical model was developed for the process based on the steady-state data collected over the range of dilution rates (20 to 110 h) and feed solids concentrations (6 to 18% w/v) studied. A modified Monod model with inhibition by arsenic was used to model bacterial ferrous ion oxidation rates. The model assumes that (i) pyrite and arsenopyrite leaching occurs solely by the action of ferric iron produced from the bacterial oxidation of ferrous iron and (ii) bacterial growth rates are proportional to ferrous ion oxidation rate. The equilibrium among the various ionic species present in the leach solution that are likely to have a significant effect on the bioleach process were included in the model. (c) 1994 John Wiley & Sons, Inc.     

Biooxidation capacity of the extremely thermoacidophilic archaeon metallosphaera sedula under bioenergetic challenge

The biooxidation capacity of an extremely thermoacidophilic archaeon Metallosphaera sedula (DSMZ 5348) was examined under bioenergetic challenges imparted by thermal or chemical stress in regard to its potential use in microbial bioleaching processes. Within the normal growth temperature range of M. sedula (70-79 degrees C) at pH 2.0, upward temperature shifts resulted in bioleaching rates that followed an Arrhenius-like dependence. When the cells were subjected to supraoptimal temperatures through gradual thermal acclimation at 81 degrees C (Han et al., 1997), cell densities were reduced but 3 to 5 times faster specific leaching rates (Fe3+ released from iron pyrite/cell/h) could be achieved by the stressed cells compared to cells at 79 degrees C and 73 degrees C, respectively. The respiration capacity of M. sedula growing at 74 degrees C was challenged by poisoning the cells with uncouplers to generate chemical stress. When the protonophore 2,4-dinitrophenol (5-10 μM) was added to a growing culture of M. sedula on iron pyrite, there was little effect on specific leaching rates compared to a culture with no protonophore at 74 degrees C; 25 μM levels proved to be toxic to M. sedula. However, a significant stimulation in specific rate was observed when the cells were subjected to 1 μM nigericin (+135%) and 2 μM (+63%); 5 μM levels of the ionophore completely arrested cell growth. The ionophore effect was further investigated in continuous culture growing on ferrous sulfate at 74 degrees C. When 1 μM nigericin was added as a pulse to a continuous culture, a 30% increase in specific iron oxidation rate was observed for short intervals, indicating a potential positive impact on leaching when periodic chemical stress is applied. This study suggests that biooxidation rates can be increased by strategic exposure of extreme thermoacidophiles to chemical or thermal stress, and this approach should be considered for improving process performance. Copyright 1998 John Wiley & Sons, Inc.     

Relative contributions of biological and chemical reactions to the overall rate of pyrite oxidation at temperatures between 30 degrees C and 70 degrees C

The stoichiometry and kinetics of the spontaneous, chemical reaction between pyrite and ferric iron was studied at 30, 45, and 70 degrees C in shake flasks at pH 1.5 by monitoring the ferrous iron, total iron, elemental sulfur, and sulfate concentration profiles in time. It was found that the sulfur moiety of pyrite was oxidized completely to sulfate. Elemental sulfur was not produced in detectable amounts. The iron moiety of pyrite was released as ferrous iron. All observed initial reaction rates could be fitted into an empirical equation. This equation includes the concentrations of ferric iron and pyrite, and a constant which is dependent on the temperature and the nature of the main anion present. It was observed that ferrous iron formed during the reaction slowed down the oxidation of pyrite by ferric iron. The extent of this effect decreased with increasing temperature. With the aid of the empirical equation, the contribution of the chemical oxidation of pyrite by ferric iron to the overall oxidation in a hypothetical plug-flow reactor, in which biologically mediated oxdidation of pyrite and ferrous iron by oxygen also takes place, can be assessed. At 30, 45, and 70 degrees C, respectively, 2, 8-17, and 43% of the pyrite was oxidized chemically by ferric iron. Therefore, it is expected that only in reactors operating at high temperatures with extremely thermophilic bacteria, will chemical oxidation cause a significant deviation from the apparent first order overall kinetics of biological pyrite oxidation.     

The effects of Fe(II) and Fe(III) concentration and initial pH on microbial leaching of low-grade sphalerite ore in a column reactor

In this study the effects of initial concentration of Fe(II) and Fe(III) ions as well as initial pH on the bioleaching of a low-grade sphalerite ore in a leaching column over a period of 120 days with and without bacteria were investigated. Four different modifications of medium were used as column feed solutions to investigate the effects of initial concentration of Fe(II) and Fe(III) ions on zinc extraction. The experiments were carried out using a bench-scale, column leaching reactor, which was inoculated with mesophilic iron oxidizing bacteria, Acidithiobacillus ferrooxidans, initially isolated from the Sarcheshmeh chalcopyrite concentrate (Kerman, Iran). The effluent solutions were periodically analyzed for Zn, total Fe, Fe(II) and Fe(III) concentrations as well as pH values. Bacterial population was measured in the solution (free cells). Maximum zinc recovery in the column was achieved about 76% using medium free of initial ferrous ion and 11.4 g/L of ferric ion (medium 2) at pH 1.5. The extent of leaching of sphalerite ore with bacteria was significantly higher than that without bacteria (control) in the presence of ferrous ions. Fe(III) had a strong influence in zinc extraction, and did not adversely affect the growth of the bacteria population.     

Acid-bacterial and ferric sulfate leaching of pyrite single crystals

Pyrite single-crystal cubes were cut, polished. and x-rayed to produce orientations of (100), (110), (111), and (112). These crystallographically developed surfaces then were prepared to expose an area of 1 cm(2), and the remainder of the crystal was coated with an acid-resistant silicone cement. Crystals with representative orientations then were leached in ferric sulfate solutions adjusted to a pH of 2.3 with H(2)SO(4) containing up to 6 x 10(3) ppm of Fe(3+) at 30 and 55 degrees C. Leaching was also conducted in acid-bacterial lixiviants containing Thiobacillus ferrooxidans at 30 degrees C and a thermophilic microorganism at 55 degrees C. Surface corrosion and pitting associated with pyrite leaching were examined by scanning electron microscopy. Pyrite leaching in ferric sulfate solutions was observed to be different when compared to acid-bacterial leaching. Ferric sulfate leaching required nearly 2 x 10(3) ppm of Fe(3+) at 30 degrees C while acid-bacterial leaching at 30 degrees C occurred without additions of Fe(3+), and values of Fe(3+) never exceeded 10(2) ppm. Because of precipitate formation, an accurate assessment of the role of crystallographic orientation on the leaching of pyrite is difficult.     

Copper removal from an industrial waste by bioleaching

Summary Copper contained in a solid industrial waste produced in a silicone manufacturing process was leached with spent iron medium from aThiobacillus ferrooxidans culture. Most effective leaching was observed in a continuously fed, dual reactor system. Spent iron medium was generated by growingT. ferrooxidans in 0.9 K iron medium at pH 1.5 in the first reactor, and was transferred to a second reactor in which it leached the copper from the waste. Leaching was effective at a pulp density of the waste material as high as 20%. In experiments run at a pulp density of 2.5%, the spent iron medium was most efficient in leaching copper when it was first diluted 100-fold with a mineral salts solution at pH 1.5. Removal of the copper from the waste appeared to involve its displacement by acid, dissolved mineral salts, and ferric iron. Potentials for practical application of this process are discussed.     

Integrated biological process for the treatment of a Chilean complex gold ore

Abstract: A process for gold recovery from a complex Chilean ore from Burladora (IV Region) which integrates concentration by flotation, bacterial leaching and cyanidation was studied at a laboratory scale. The chemical composition of the ore is 8.2% Fe, 0.78% Cu, 0.88% As and 3.5 g/t Au, with pyrite, hematite, covelite, arsenopyrite and chalcopyrite as the main metal-bearing minerals. The initial gold recovery by conventional cyanidation on a crushed ore sample was only 54%. The ore was ground and concentrated by flotation with a gold recovery of only 56%. The gold content of the concentrate is 17 g/I Au. Concentrate samples were leached in 1.5 l stirred reactors at 10% pulp density in 1000 ml of acid medium (pH 1.8). Some experiments were inoculated with harvested bacteria previously isolated from mining solutions. Dissolved metals, pH and bacteria concentration in the leaching solutions were periodically determined. In the presence of bacteria, oxidation of the ferrous ion produced by acid dissolution of the concentrate was observed, and after 4 days of leaching 100% of the dissolved iron was present as ferric ion. Gold recovery by cyanidation increased from 13% for the initial concentrate to 34% after 10 days of chemical acid leaching and 97% after 10 days of bacterial leaching. To increase the total gold recovery, the flotation tailings were submitted to cyanidation. A complete flowsheet of the process and a first economical evalualion are proposed. As a possible alternative process, heap bacterial leaching and further cyanidation of the ore are suggested.