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.     

Leaching of Pyrites of Various Reactivities by Thiobacillus ferrooxidans

Wide variations were found in the rate of chemical and microbiological leaching of iron from pyritic materials from various sources. Thiobacillus ferrooxidans accelerated leaching of iron from all of the pyritic materials tested in shake flask suspensions at loadings of 0.4% (wt/vol) pulp density. The most chemically reactive pyrites exhibited the fastest bioleaching rates. However, at 2.0% pulp density, a delay in onset of bioleaching occurred with two of the pyrites derived from coal sources. T. ferrooxidans was unable to oxidize the most chemically reactive pyrite at 2.0% pulp density. No inhibition of pyrite oxidation by T. ferrooxidans occurred with mineral pyrite at 2.0% pulp density. Experiments with the most chemically reactive pyrite indicated that the leachates from the material were not inhibitory to iron oxidation by T. ferrooxidans.     

Ferrous ion oxidation by Thiobacillus ferrooxidans immobilized in calcium alginate

Summary Thiobacillus ferrooxidans was immobilized by entrapment into calcium alginate matrix. The immobilized bacteria were used in packed-bed column reactors for the continuous oxidation of ferrous ion at pH 1.5. The presence of mineral salts resulted in a shorter lag period before a steady-state of about 95% iron oxidation was achieved. Parallel shake flask experiments were used to evaluate pH, mineral salts, and alginate toxicity as factors influencing biological iron oxidation. Manometric experiments indicated that the previous growth history of T. ferrooxidans was important in determining the rate of iron oxidation. Scanning electron microscopy and energy dispersive analysis of X-rays were used to characterize bacteria entrapped in calcium alginate and the enrichment of iron in the matrix.     

Evaluation of the Biotechnological Potential of Pure and Mixture of Indigenous Iron-Oxidizing Bacteria to Dissolve Trace Metals from Cu Bearing Ore

Abstract

This study aimed to investigate the ability of pure and consortia of indigenous iron-oxidizing bacteria to enhance the dissolution of trace metals from Cu and Zn-bearing ore. Three bacterial strains Acidithiobacillus ferrooxidans strain WG101, Leptospirillum ferriphilum strain WG102, Leptospirillum ferrooxidans strain WG103 isolated from Baiyin copper mine, China were used in this study. The biotechnological potential of these indigenous isolates was evaluated both in pure and in consortia to extract cobalt, chromium, and lead from the copper and zinc bearing ore. The sulfur and iron-oxidizing bacterial isolate Acidithiobacillus ferrooxidans strain WG101 exhibited efficient dissolution compared to sole iron-oxidizing Leptospirillum ferriphilum strain WG102, and Leptospirillum ferrooxidans strain WG103. Initial medium pH, pulp density, and temperature were studied as influential parameters in bioleaching carried out by bacterial consortia. The achieved optimum conditions were; initial pH of 1.5, 10% of pulp density, and temperature 30?°C with 68.7?±?3.9% cobalt, 56.6?±?3.9% chromium, and 36?±?3.7% lead recovery. Analytical study of oxidation-reduction potential and pH fluctuation were observed during this whole process that shows the metal dissolution efficiency of bacterial consortia. Alterations in spectral bands of processed residues were reported through FTIR analysis compared with control ore sample. Mössbauer spectroscopy analysis showed the influence of bacterial consortia on iron speciation in bioleached samples. The findings confirm that the indigenous acidophilic iron-oxidizing bacterial strains are highly effective in the dissolution of trace elements present in ore samples. This study not only supports the notion that indigenous bacterial strains are highly effectual in metal dissolution but provides the basic vital conditions to upscale the bioleaching technique for metals dissolution.     

Continuous microbial leaching of a pyritic concentrate by Leptospirillum-like bacteria

Summary Continuous leaching of a pyritic flotation concentrate by mixed cultures of acidophilic bacteria was studied in a laboratory scale airlift reactor. Enrichment cultures adapted to the flotation concentrate contained Thiobacillus ferrooxidans and Thiobacillus thiooxidans. During the late stationary growth phase of these thiobacilli growth of Leptospirillum-like bacteria was observed, too. In discontinuous cultivation no significant influence of Leptospirillum-like bacteria on leaching rates could be detected. During continuous leaching at pH 1.5 Leptospirillum-like bacteria displaced Thiobacillus ferrooxidans. The iron leaching rate achieved by Leptospirillum-rich cultures was found to be up to 3.9 times higher than that by Leptospirillum-free cultures.     

Bioleaching of chalcopyrite by pure and mixed cultures of Acidithiobacillus spp. and Leptospirillum ferriphilum

Bioleaching is an economical method for the recovery of metals that requires low investment and operation costs. Furthermore, it is generally more environmentally friendly than many physicochemical metal extraction processes. The bioleaching of chalcopyrite in shake flasks was investigated with pure and mixed cultures of Acidithiobacillus ferrooxidans, Acidithiobacillus thiooxidans, Acidithiobacillus caldus, and Leptospirillum ferriphilum. The mixed cultures containing both iron- and sulfur-oxidizing bacteria were more efficient than the pure culture alone. The presence of sulfur-oxidizing bacteria positively increased the dissolution rate and the percentage recovery of copper from chalcopyrite. Mixed cultures consisting of moderately thermophilic L. ferriphilum and A. caldus leached chalcopyrite more effectively than mesophilic A. ferrooxidans pure and mixed cultures. The decrease of the chalcopyrite dissolution rate in leaching systems containing A. ferrooxidans after 12–16 days coincided with the formation of jarosite precipitation as a passivation layer on the mineral surface during bioleaching. Low pH significantly reduces jarosite formation in pure and mixed cultures of L. ferriphilum and A. caldus.     

The Effect of the Facultative Chemolithotrophic Bacterium Thiobacillus acidophilus on the Leaching of Low-Grade Cu-Ni Sulfide Ore by Thiobacillus ferrooxidans

The purpose of this investigation was to determine the effect of Thiobacillus acidophilus on the leaching of a low-grade Cu-Ni sulfide ore by Thiobacillus ferrooxidans. A sample of low-grade Cu-Ni sulfide ore containing 0.36% Cu, 0.48% Ni, and 7.87% Fe was pulverized and initially leached for a 21-day period using two different pure cultures of T. ferrooxidans, an environmental strain (F2) and a strain from the American Type Culture Collection (ATCC 23270). Samples of the ore slurries were drawn and the pH was monitored over the course of the leaching period. The concentrations of Cu and Ni leached by each strain were determined and compared. No significant differences were observed in the concentrations of Cu and Ni leached by the two pure cultures of T. ferrooxidans. Subsequently, the ore was leached with mixed cultures of T. ferrooxidans and T. acidophilus to determine the effect of the latter on the concentrations of Cu and Ni leached from the ore. The environmental strain F2 of T. ferrooxidans was used in combination with both a type strain (ATCC 27807) and an environmental strain (64) of T. acidophilus. After 21 days, the mixed cultures of T. ferrooxidans and T. acidophilus leached significantly greater amounts of copper than the pure strain alone, but no such difference was observed for the leaching of nickel.     

Bioleaching of chalcopyrite concentrate by a moderately thermophilic culture in a stirred tank reactor

A mixed culture of moderately thermophilic microorganisms was enriched from acid mine drainage samples collected from several chalcopyrite mines in China. Such mixed culture can be used to effectively extract copper from chalcopyrite. Furthermore, after being adapted to gradually increased concentration of chalcopyrite concentrate, the tolerance of the mixed culture to chalcopyrite concentrate was brought up to 80 g/L. The effects of several leaching parameters on copper recovery in stirred tank reactor also had been investigated. The results of the investigation show that it was possible to achieve a copper extraction rate of 75% in 44 days at a pulp density of 8%. The leaching rate of chalcopyrite concentrate tended to increase with dissolved total iron concentration. At low pH ranges, more microscopic counts of microorganisms were found in the solution. Furthermore, the analysis of leached residues indicates that the passivation of chalcopyrite concentrate was mainly due to a mass of jarosite and PbSO(4) on the mineral surface, other than the elemental sulphur layer. The bacterial community composition was analyzed by using Amplified Ribosomal DNA Restriction Analysis. Two moderately thermophilic bacteria species were identified as Leptospirillum ferriphilum and Acidithiobacillus caldus with abundance of 67% and 33% in the bio-pulp, respectively.     

Bioleaching of spent fluid catalytic cracking catalyst using Aspergillus niger

The use of the fungus Aspergillus niger for the bioleaching of heavy metals from spent catalyst was investigated, with fluid catalytic cracking (FCC) catalyst as a model. Bioleaching was examined in batch cultures with the spent catalysts at various pulp densities (1-12%). Chemical leaching was also performed using mineral acids (sulphuric and nitric acids) and organic acids (citric, oxalic and gluconic acids), as well as a mixture of organic acids at the same concentrations as that biogenically produced. It was shown that bioleaching realised higher metal extraction than chemical leaching, with A. niger mobilizing Ni (9%), Fe (23%), Al (30%), V (36%) and Sb (64%) at 1% pulp density. Extraction efficiency generally decreased with increased pulp density. Compared with abiotic controls, bioleaching gave rise to higher metal extractions than leaching using fresh medium and cell-free spent medium. pH decreased during bioleaching, but remained relatively constant in both leaching using fresh medium and cell-free spent medium, thus indicating that the fungus played a role in effecting metal extraction from the spent catalyst.     

Oxidation of stibnite byThiobacillus ferrooxidans

Optimum pH, temperature and pulp density for microbiological leaching of museum-grade stibnite mineral has been investigated using a stibnite-adapted strain ofThiobacillus ferrooxidans. Optimum conditions were found to be pH 1.75, 35 C and 12 g solid substrate per 100 ml of basal salts medium as the initial dose. The energy of activation was determined to be 16.8 kcal per mole, and the temperature coefficient 2.2. The highest total dissolved-antimony concentration, [Sb_t] = [Sb⁺³] + [Sb⁺⁵] + [SbO⁺] + [SbO₂ ⁺], was about 1400 mg/litre, due to relatively low solubility of (SbO)₂SO₄ and (SbO₂)₂SO₄.     

Microbiological leaching of a chalcopyrite concentrate by Thiobacillus ferrooxidans

The microbiological leaching of a chalcopyrite concentrate has been investigated using a pure strain of Thiobacillus ferrooxidans. The optimum leaching conditions regarding pH, temperature, and pulp density were found to be 2.3, 35°C, and 22%, respectively. The energy of activation was calculated to be 16.7 kcal/mol. During these experiments the maximum rate of copper dissolution was about 215 mg/liters/hr and the final copper concentration was as high as 55 g/liter. This latter value is in the range of copper concentrations which may be used for direct electrorecovery of copper. Jarosite formation was observed during the leaching of the chalcopyrite concentrate. When the leach residue was reground to expose new substrate surface, subsequent leaching resulted in copper extractions up to about 80%. On the basis of this experimental work, a flow sheet has been proposed for commercial scale biohydrometallurgical treatment of high-grade chalcopyrite materials.     

Optimization of Microbial Leaching of Base Metals from a South African Sulfidic Nickel Ore Concentrate by Acidithiobacillus ferrooxidans

X-ray diffraction analysis revealed that pentlandite and chalcopyrite were the prominent mineral phases in a South African sulfidic nickel ore concentrate that hosted nickel and copper. Cobalt was found to be closely associated with the nickel-bearing pentlandite phase of the ore sample. Microbial batch leaching experiments designed according to a central composite design model were run for 15 days in a shaking incubator (150 rpm) at a constant temperature (30°C) with variations in experimental parameters like ore pulp density, particle size, bacterial inoculum, pH of the culture medium, and residence time. Quadratic mathematical models were developed to predict the rate of metal extractions. The suitability of the model of the microbial leaching process was confirmed from normal probability curves. An analysis of variance indicated that the residence time, pulp density of the ore, and particle size were the most significant factors. Bacterial inoculum size hardly showed any effect on the total metal extractions. Maximum nickel (82%), cobalt (76%) and copper (25.6%) extractions were achieved under optimum conditions, operated for 15 days at pulp density of 2% and particle size of ?75 µm at pH 1.5.     

Effect of Activated Carbon Addition on the Conventional and Electrochemical Bioleaching of Chalcopyrite Concentrates

The effect of activated carbon addition on the rate and efficiency of copper mobilization from Sarcheshmeh chalcopyrite concentrate was studied in the presence and absence of a mixed culture of moderately thermophilic microorganisms. Conventional leaching at a 10% (w/v) pulp density in 500-ml Erlenmeyer flasks on a rotary shaker at 150 rpm, and electrochemical bioleaching in a stirred bioreactor at an ORP (oxidation-reduction potential) range of 400 to 430 mV measured against a Ag/AgCl reference electrode. The bioreactor contained ore concentrate at a pulp density of 20%, which was stirred at 600 rpm. All experiments were conducted in the presence and absence of 3 g/L activated carbon, at initial pH 1.5, temperature 50°C, in Norris's nutrient medium with an addition of 0.02% (w/v) yeast extract. The results showed that the addition of activated carbon increased the rate and yield of copper extraction from the concentrate especially in the presence of bacteria. Final recovery after 20 days was 52% and 44% in the shake flask experiments with and without carbon addition, respectively. Enhanced rates of copper mobilization were achieved in the electrochemical bioleaching experiments in which copper was leached selectively relative to iron. Final copper recovery after 10 days was 85% and 77% in the presence and absence of activated carbon, respectively. The positive effect of activated carbon on copper extraction could be related to the galvanic interaction between the inert carbon as cathode and chalcopyrite as anode. The bacterial elimination of sulfur produced on the sulfide minerals during chemical leaching is assumed to intensify the galvanic interaction. It seems that maintaining the ORP at a low potential and efficient mixing improves the bacterial and chemical subsystems in the electro-bioreactor that accelerates the rate of copper mobilization from the concentrate.     

Microbial recycling of mineral waste products

The applicability of biotechnological methods to metal recovery from non-sulfide industrial waste products (slag, galvanic sludge, filter-press residue, filter dust, and fly ash) was investigated. From some products, copper, chromium, zinc or vanadium were completely extracted by sulfuric acid produced by Thiobacillus thiooxidans. The efficiency of bacterial metal solubilization varied depending on the type of waste material and on the pulp density. Stepwise increase of pulp density promoted bacterial growth and activity, resulting in metal concentrations of 6.6 g Cu/l, 6.3 g V/l, 24.4 g Zn/l or 21 g Cr/l in the leaching medium. In some cases bacterial leaching was as effective as chemical leaching with sulfuric acid. The efficiency of both processes is considered. In principal, bacterial metal recovery from industrial waste products seems to be feasible and may contribute to an increase in future supplies of raw materials, as well as to detoxification of industrial waste products resulting in reduced environmental pollution problems.     

Role of cell attachment in leaching of chalcopyrite mineral by Thiobacillus ferrooxidans

Summary Experiments on the leaching of copper from chalcopyrite mineral by the bacterium Thiobacillus ferrooxidans show that, in the presence of adequate amounts of sulphide, iron-grown bacteria preferentially oxidise sulphur in the ore (through direct attachment) rather than ferrous sulphate in solution. At 20% pulp density, the leaching initially takes place by a predominantly direct mechanism. The cell density in the liquid phase increases, but the Fe²⁺ is not oxidised. However, in the later stages when less solid substrate is available and the cell density becomes very high, the bacteria start oxidising Fe²⁺ in the liquid phase, thus contributing to the indirect mechanism of leaching. Contrary to expectations, the rate of leaching increased with increasing particle size in spite of the decreasing specific surface area. This has been found to be due to increasing attachment efficiency with increase in particle size. Offprint requests to: R. Kumar     

The removal of pyritic sulphur from coal by Leptospirillum-like bacteria

Summary The microbial oxidation of pyritic sulphur was studied in a 4.5-l airlift fermentor at pH 1.5 and 100 g/l pulp density. By microbial leaching with Leptospirillum-like bacteria 85% of the pyritic sulphur was removed within 40 days; 30% of the removed pyrite was oxidized to elemental sulphur, the rest being transformed to soluble sulphate. Accumulation of elemental sulphur could be avoided by using a mixed culture of Leptospirillum-like bacteria and Thiobacillus ferrooxidans. Apart from oxidation of elemental sulphur neither the pure nor the mixed culture showed a significant difference as to removal of pyrite.     

Continuous culture of Thiobacillus ferrooxidans on a zinc sulfide concentrate

A zinc sulfide concentrate was leached microbiologically by Thiobacillus ferrooxidans in a continuous stirred tank reactor. A model was developed to predict, the leaching kinetics when the bacterial growth rate was not limited by any substrate other than the zinc concentrate, and it was modified to explain the observed results. Stable steady sates were obtained over a range of dilution rates from 0.0171 to 0.1038 hr^?1. Because a solid substrate was used, the specific growth rate of the bacaeria was not a unique function of the subastrate concentration, and conventional contnuous culture theory based on the Monod equation did not apply to this system. The leaching rates and bacterial growth rates were first order in mineral surface area cocentration.     

Bioleaching of uranium from low grade black schists by <Emphasis Type="Italic">Acidithiobacillus ferrooxidans</Emphasis>

Summary The feasibility of bacterial recovery of uranium from the low grade black schists occurring in the Okcheon district, South Korea, was investigated. Following the introduction of Acidithiobacillus ferrooxidans, 80% of the uranium could be extracted from the schists, which contain 0.01% U₃O₈ by weight, within 60 h at a pulp density of 100 g-ore/l. Only 18% of the uranium was extracted without microbial activity. The uranium-leaching efficiency was not greatly affected by the addition of Fe²⁺ in the range of 5–9 g/l, and the leaching efficiency of uranium from the schists by A. ferrooxidanscould be efficiently maintained at high pulp densities (up to 500 g-ore/l).     

Leaching of copper ore of the Udokanskoe deposit at low temperatures by an association of acidophilic chemolithotrophic microorganisms

Pure cultures of indigenous microorganisms Acidithiobacillus ferrooxidans strain TFUd, Leptospirillum ferrooxidans strain LUd, and Sulfobacillus thermotolerans strain SUd have been isolated from the oxidation zone of sulfide copper ore of the Udokanskoe deposit. Regimes of bacterial-chemical leaching of ore have been studied over a temperature range from −10 to +20°C. Effects of pH, temperature, and the presence of microorganisms on the extraction of copper have been shown. Bacterial leaching has been detected only at positive values of temperature, and has been much more active at +20 than at +4°C. The process of leaching was more active when the ore contained more hydrophilic and oxidized minerals. The possibility of copper ore leaching of the Udokanskoe deposit using sulfuric acid with pH 0.4 at negative values of temperature and applying acidophilic chemolithotrophic microorganisms at positive values of temperature and low pH values was shown.     

Bioleaching of zinc sulfide concentrate by Thiobacillus ferrooxidans

The kinetics of the bioleaching of ZnS concentrate by Thiobacillus ferrooxidans was studied in a well-mixed batch reactor. Experimental studies were made at 30 degrees C and pH 2.2 on adsorption of the bacteria to the mineral, ferric iron leaching, and bacterial leaching. The adsorption rate of the bacteria was fairly rapid in comparison with the bioleaching rate, indicating that the bacterial adsorption is at equilibrium during the leaching process. The adsorption equilibrium data were correlated by the Langmuir isotherm, which is a useful means for predicting the number of bacteria adsorbed on the mineral surface. The rate of chemical leaching varied with the concentration of ferric iron, and the first-order reaction rate constant was determined. Bioleaching in an iron-containing medium was found to take place by both direct bacterial attack on the sulfide mineral and indirect attack via ferric iron. In this case, the ferric iron was formed from the reaction product (ferrous iron) through the biological oxidation reaction. To develop rate expressions for the kinetics of bacterial growth and zinc leaching, the two bacterial actions were considered. The key parameters appearing in the rate equations, the growth yield and specific growth rate of adsorbed bacteria, were evaluated by curve fitting using the experimental data. This kinetic model allowed us to predict the liquid-phase concentrations of the leached zinc and free cells during the batch bioleaching process.