Bioleaching of spent refinery processing catalyst using Aspergillus niger with high-yield oxalic acid

A spent refinery processing catalyst was physically and chemically characterized, and subjected to one-step and two-step bioleaching processes using Aspergillus niger. During bioleaching of the spent catalysts of various particle sizes ("as received", 100-150 microm, <37 microm, and x =2.97 (average) microm) and pulp densities, the biomass dry weight and pH were determined. The corresponding leach liquor was analysed for excreted organic acids along with heavy metal values extracted from the catalyst. Chemical characterization of the spent catalyst confirmed the presence of heavy metal including Al (33.3%), Ni (6.09%) and Mo (13.72%). In general, the presence of the spent catalyst caused a decrease in the biomass yield and an increase in oxalic acid secretion by A. niger. The increase in oxalic acid secretion with a decrease in the catalyst particle size (up to <37 microm) led to corresponding increase in the extraction of metal values. The highest extraction of metal values from the spent catalyst (at 1% w/v pulp density and particle size <37 microm) were found to be 54.5% Al, 58.2% Ni and 82.3% Mo in 60 days of bioleaching. Oxalic acid secretion by A. niger in the presence of the spent catalyst was stimulated using 2-[N-Morpholino]ethanesulfonic acid (MES) buffer (pH 6), which resulted in comparable metal extraction (58% Al, 62.8% Ni and 78.9% Mo) in half the time required by the fungus in the absence of the buffer. Spent medium of A. niger grown in the absence and in the presence of MES buffer were found to leach almost similar amounts of Al and Ni, except Mo for which the spent medium of buffered culture was significantly more effective than the non-buffered culture. Overall, this study shows the possible use of bioleaching for the extraction of metal resources from spent catalysts. It also demonstrated the advantages of buffer-stimulated excretion of organic acids by A. niger in bioleaching of the spent catalyst.     

Use of adapted Aspergillus niger in the bioleaching of spent refinery processing catalyst

Spent refinery processing catalyst is listed as a hazardous waste; the toxicity characteristic leaching procedure (TCLP) extracts of the catalyst are found to contain heavy metals at concentrations exceeding the regulated levels. In the present investigation, Aspergillus niger was adapted to single metal ions Ni, Mo or Al (at 100-2,000 mg/L in steps of 100mg/L) and then to a mixture of Ni, Mo and Al (at a mass ratio of 1:2:6, as approximately present in the spent catalyst). Adaptation experiments with single metals showed that the fungus could tolerate up to 1,000 mg/L Ni, 1,200 mg/L Mo and 2,000 mg/L Al. In the presence of a mixture of these metals, the fungus was able to tolerate up to 100mg/L Ni, 200mg/L Mo and 600 mg/L Al. One-step bioleaching experiments with 1 wt% spent catalyst (of particle size <37 microm) were carried out using un-adapted and various adapted fungal strains. In contrast to the adapted strains, the un-adapted strain showed no growth in the presence of the catalyst. Ni:Mo:Al-adapted strain was the most efficient in the leaching of metals from the catalyst (at 78.5% Ni, 82.3% Mo and 65.2% Al) over 30 days due to its tolerance to the toxic elements at 1 wt%. More importantly, the Ni:Mo:Al-adapted strain was capable of bioleaching up to 3 wt% spent catalyst. The TCLP extracts of the spent catalyst after bioleaching using the Ni:Mo:Al-adapted strain showed the concentrations of Ni and Mo were well within the regulated levels.     

Heavy metals extraction from municipal solid waste incineration fly ash using adapted metal tolerant Aspergillus niger

This study focused on the adaptation of Aspergillus niger tolerating high concentration of heavy metals for bioleaching of fly ash. The Plackett-Burman design indicated that Al and Fe inhibited the growth of A. niger (AS 3.879 and AS 3.40) significantly. The single metal (Al and Fe) and multi-metals adapted AS 3.879 strain tolerated up to 3500 mg/L Al, 700 mg/L Fe, and 3208.1mg/L multi-metals, respectively. The order of metal extraction yield in two-step bioleaching of 60 and 70 g/L fly ash using Al adapted, multi-metals adapted and un-adapted AS 3.879 strains was as follows: multi-metals adapted>Al adapted>un-adapted. The multi-metals adapted strain grew with up to 70 g/L fly ash and secreted 256 mmol/L organic acids after 288 h, where 87.4% Cd, 64.8% Mn, 49.4% Zn and 45.9% Pb were dissolved. The extracted metals in TCLP test of the bioleached fly ash by multi-metals adapted strain were under the regulated levels in China.     

Bioleaching of copper from chalcopyrite ore by fungi

Microorganisms have been geologically active in mineral formation, mineral diagenesis and sedimentation via direct action of their enzymes or indirectly through chemical action of their metabolic products. This property of microorganisms is being harnessed during the recent years for extraction of metals from their ores, especially from low-grade ores. In the present study bioleaching of copper from its low-grade chalcopyrite ore using 26 isolates of acidophilic fungi is reported. Most of these fungal strains belonged to the genera Aspergillus, Penicillium and Rhizopus. The leaching experiments were conducted in Czepek Dox minimal medium containing 1% (100 mesh) ore with shaking at room temperature for 20 days. Out of these, 4 isolates exhibited significant bioleaching activities. Maximum leaching of copper (78 mg/L) was observed with Aspergillus flavus (DSF-8) and Aspergillus niger (DOF-1). Nutritional and environmental conditions for optimum bioleaching were standardized. Present study indicates the usefulness of acidophilic fungi in bioleaching of copper from its low-grade ores.     

Chemical constituents and antibacterial activity of the leaf essential oil of <Emphasis Type="Italic">Feronia limonia</Emphasis>

Bioleaching of uranium was carried out with Turamdih ore sample procured from Uranium Corporation of India Limited, Jaduguda. The bacterial strain that was used in the leaching experiments was isolated from the Jaduguda mine water sample. Efficiency of bioleaching was studied by varying parameters like pulp density and initial ferrous concentration as source of energy. It is observed that the efficiency of bioleaching was 49% at 10% pulp density (w/v) and initial pH 2.0. Addition of external has no effect on efficiency of bioleaching showing domination of direct leaching mechanism over indirect.     

Beneficiation of iron ore slime using Aspergillus niger and Bacillus circulans

Studies were carried out on the removal of alumina from iron ore slime containing (%) Fe(2)O(3) 75.7, Al(2)O(3) 9.95, SiO(2) 6.1, Fe (total) 52.94 with the help of Bacillus circulans and Aspergillus niger. B. circulans and A. niger showed 39% and 38% alumina removal after six and 15 days of in situ leaching at 10% pulp density, respectively. Culture filtrate leaching with A. niger removed 20% alumina at 2% pulp density with 13 day old culture filtrate. B. circulans was more efficient than A. niger for selective removal of alumina. In case of A. niger in situ leaching rather than culture filtrate leaching was found to be more effective.     

Leaching Heavy Metals from Contaminated Soil by Using Thiobacillus ferrooxidans or Thiobacillus thiooxidans

Iron- and sulfur-oxidizing bacteria identified as Thiobacillus ferrooxidans and T. thiooxidans were successfully enriched from various soil samples contaminated with heavy metals and organic compounds. Depending on the growth medium, the soil sample, and the type of contaminant, the indigenous isolates solubilized &gt; 50% of most of the heavy metals present in the solid sample (As, Cd, Co, Cr, Cu, Ni, V, Zn, B, Be). Leaching with T. ferrooxidans strains resulted in total extraction of Cd, Co, Cu, and Ni. With sulfur-oxidizing bacteria &gt; 80% of Cd, Co, Cu, and Zn was mobilized from rainwater sludge. Pb and Ba were not detected in the leachate, given the insolubility of their sulfate compounds. An increase in pulp density up to 20%, indicating 6.6% total organic carbon in the soil and rubble leach experiment (sample 557), did not inhibit the growth of the indigenous T. ferrooxidans strain. In view of these results, bioleaching appears to have some potential for remediation of heavy metal contaminated soils.     

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.     

Solubilization of cobalt from ocean nodules at neutral pH—a novel bioprocess

A marine organism (Bacillus M1) isolated from Indian Ocean manganese nodules was characterized. The organism grew well in artificial seawater medium, at near neutral pH, 30°C and 0.25 M NaCl, and showed MnO₂-reducing activity. Growing cultures of Bacillus M1 as well as cell-free spent liquor from fully-grown cultures were employed to extract metals from the nodules. The spent liquor of cultures of the organism could dissolve around 45% cobalt (Co) at a pH of 8.2 in 2 h. Co recovery by this treatment was comparable to that in acidic leaching with 2.5 M hydrochloric acid solutions, and was independent of pulp density (w/v ratio). The amount of Co dissolved was beyond the thermodynamic solubility limit in aqueous solution at a pH of 8.2. It is inferred that the metabolites present in the spent liquor played a pivotal role in complexing the Fe (III) phase, solubilizing Co in the process. Partial characterization of spent liquor by spot tests, UV visible spectroscopy and FTIR spectroscopy, showed the presence of siderophore-like phenolic compound(s) with an attached carboxyl group that might form soluble organic complexes with Fe (III).     

Bioleaching and bioprecipitation of nickel and iron from laterites

Abstract: Leaching of silicate ores, particularly nickel laterites, with the aid of heterotrophic organisms has been briefly reviewed. Samples of laterite ores from Greece were characterised mineralogically and a number of microorganisms isolated from them. One of these organisms (code FI) was successfully acclimatized to 6400 ppm nickel. Samples of the high-grade Greek Kastoria nickel laterite were leached with sulphuric acid and a number of organic acids. Sulphuric and citric acids extracted over 60 and 40% of the contained nickel, respectively, but the other acids employed were less efficient leachants. Oxalic acid precipitated nickel oxalate. Roughly the same extraction of iron was observed. The main leaching parameter was confirmed to be hydrogen ion concentration, although complexation with organic anions was a contributor. Organism FI (a strain of Penicillium ) was used in comparison with organisms from various culture collections to bioleach nickel from samples of the low-grade Greek Litharakia nickel laterite. The organisms were cultivated in a mixture of a sugar-based nutrient mineral medium and finely ground ore. Several penicillia and aspergilli leached 55–60% of the contained nickel and cobalt, and 25–35% of the iron when sucrose was the carbon source, but FI was not efficient. However, in molasses medium, Fl extracted nearly 40% of the nickel. Biosorption and bioprecipitation reactions were observed. The mechanism of bioleaching or in situ leaching is discussed in terms of close physical and chemical association between the fungal hyphae and mineral phases in the ore. This accounted for the low overall hydrogen ion concentration observed during bioleaching.     

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.     

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.     

Enhancing Manganese Recovery from Low-Grade Ores by Using Mixed Culture of Indigenously Isolated Bacterial Strains

Conventional leaching methods for manganese (Mn) recovery require strong acids and are threatening to the environment. Alternatively, the use of microbes for Mn recovery is environment friendly in nature. The present investigation compares the capacity of pure and mixed cultures of native bacterial strains for bioleaching of low-grade Mn ores. The ability of the isolated microorganisms to recover Mn was evaluated in shake flasks for 20 days under optimized conditions of pulp density (2%), sucrose concentration (2 g/100 mL), initial pH 6.5, and 30°C incubation temperature. In pure culture form, Acinetobacter sp. MSB 5 (70%) was found to have a higher bioleaching potential than Lysinibacillus sp. MSB 11 (67%). Mixed culture of Acinetobacter sp. MSB 5 and Lysinibacillus sp. MSB 11 was found to perform better than the pure cultures with 74% extraction of Mn. The presence of mixed culture increased the dissolution rate and the recovery percentage of Mn. The respective growth pattern of the cultures was in synchronization to their Mn bioleaching performances. This study underlines the importance of mixed cultures and Mn solubilizing activity of native bacterial strains for efficient Mn biorecovery.     

Differential bioleaching of copper by mesophilic and moderately thermophilic acidophilic consortium enriched from same copper mine water sample

Three acidophilic enrichment consortium were developed from mine water sample of copper mine site at Khetri, India were compared for their copper leaching efficiency. Out of these one was mesophilic (35 degrees C) and two were moderately thermophilic (50 degrees C). Consortia were named as mesophilic acidophilic chemolithotrophic consortia (MACC), thermophilic acidophilic chemolithotrophic consortia (TACC), and Sulfobacillus acidophilic consortia (SAC). Copper extraction ability of both the thermophilic consortia (77-78% extraction) was almost double to that of mesophilic consortia (40% extraction) at 10% pulp density after 55 days. Both the thermophilic consortia were equally effective in leaching of other metals like Ni, Co, Zn, Mn. After 55 days, the percentage of extractions of copper by TACC was 76, 74, 67, 48 and 45 at 5%, 10%, 15%, 20% and 30% pulp density, respectively. Total number of bacteria was maximum at 5% pulp density which decreases with increase in pulp density. Sulfobacillus-like bacteria were seen in the Sulfobacillus enrichment cultures. Moderately thermophilic consortia proved to be better in leaching performance than the mesophilic counterpart.     

Effects of key parameters in recycling of metals from petroleum refinery waste catalysts in bioleaching process

Environmental laws concerning spent catalysts disposal have become increasingly more severe in recent years. Due to the toxic nature of spent catalysts, their disposal can pollute the environment. The recovery of heavy metals decreases the environmental impact of the waste catalysts and the recycled product can be further used for industrial purposes. Bio-hydrometallurgical approaches, such as bioleaching, appear to offer good prospects for recovering valuable metals from spent refinery catalysts. Currently, identifying and modifying the parameters that influenced the efficiency of bioleaching is important for industrial sector. The biological system can be further improved through optimizing the bioleaching parameters, such as the nutrient culture media, amount of oxygen and carbon dioxide, pH, temperature, inoculum, metal resistance of microorganisms, chemistry of solid waste, particle size of solid waste, solid liquid ratio, bioleaching period, size of substrate, shaking speed, and also the development of more effective bioleaching microorganisms. In our previous review (Asghari et al. in J Ind Eng Chem 19:1069–1081, 2013), information available in the literature on the bioleaching fundamentals of spent catalysts with a focus on recent developments was reviewed in detail. In this study, the effects of most important factors that influence an efficient bioleaching process of spent refinery catalysts with the hope that these valuable and useful data can help determine the most efficient process will be discussed. The details of metals recovery with a focus on the effects of different variables in the bioleaching such as reaction time, pulp density, initial pH, particle size, nutrient concentration, temperature and buffer will also be presented.     

Direct and Indirect Bioleaching of Cobalt from Low Grade Laterite and Pyritic Ores by Aspergillus niger

Abstract

The bioleaching efficiency and mechanism of recovery of cobalt (Co) and nickel from laterites and pyritic ores by Aspergillus niger were investigated. Recoveries of Co from laterites and pyritic ores by direct bioleaching were 65.9?±?1.8% and 4.9?±?2.7%, respectively, while 30.9?±?0.6% and 10.9?±?6.2% recovery of Ni were obtained from laterites and pyritic ores, respectively. Recovery of Co via indirect bioleaching in the absence of the fungal biomass from laterite was significantly lower when compared with Co released by direct bioleaching. In the latter, hyphal penetration and colonization of the laterites were clearly observed by scanning electron microscopy (SEM). X-ray powder diffraction (XRPD) analysis of mineral phases before and after bioleaching indicated that cobalt-bearing goethite was the main phase bioleached in the laterites. No significant difference was found between Co recoveries from synthesized cobalt-bearing goethite by both direct and indirect bioleaching. Therefore, we propose that two processes are involved in bioleaching from laterites: (1) cobalt-bearing goethite was exposed via direct interactions between the fungus and the minerals and (2) cobalt-bearing goethite was dissolved by released metabolites of A. niger, such as organic acids. An incongruent pattern of Co and Fe bioleaching from the laterites was also a feature of the metal recovery process.     

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.     

Bioleaching of nickel from equilibrium fluid catalytic cracking catalysts

Summary This study investigates the possibility of reusing metal-contaminated equilibrium fluid catalytic cracking (FCC) catalyst after bioleaching. Leaching with Aspergillus niger culture was found to be more effective in the mobilization of nickel from the catalyst particles compared to chemical leaching with citric acid. Bioleaching achieved 32% nickel removal whereas chemical leaching achieved only 21% nickel removal from catalyst particles. The enhanced nickel removal from the catalysts in the presence of A. niger culture was attributed to the biosorption ability of the fungal mycelium and to the higher local concentration of citric acid on the catalyst surface. It was found that 9% of solubilized nickel in the liquid medium was biosorbed to fungal biomass. After nickel leaching with A. niger culture, the hydrogen-to-methane molar ratio and coke yield, which are the measures of dehydrogenation reactions catalysed by nickel during cracking reactions, decreased significantly.     

高矿浆浓度下黄铜矿浸出过程中微生物群落结构变化规律

目的：为阐明微生物群落演替及功能与浸出效率之间关系奠定基础,以及如何提高黄铜矿生物浸出效率和铜回收率提供理 论依据。方法：通过连续传代培养进行驯化,使得复合菌群的矿浆浓度耐受能力达到25 %（w/v）。采用该复合菌群在25 %矿浆浓 度下浸出黄铜矿,同时利用变性梯度凝胶电泳和克隆文库技术分析浸出过程中的微生物多样性。最后,采用实时荧光定量PCR 对 浸出过程中微生物群落结构进行定量解析。结果：28天内黄铜矿浸出率能够达到95.1 %,而驯化前的浸出率只有51.5%。该复合 菌群主要由Acidithiobacillus caldus, Sulfobacillus acidophilus,和Fereoplasma theroplasma thermophilum组成,其中Acidithbacillus caldus是浸出前期和后期的优势种群,而Sulfobacillus acidophilus在浸出中期均有竞争优势, Ferroplasma thermophilum在整个浸出过程中占 据整个群落的比例均较低。结论：本研究获得的复合菌群具有较强的浸出黄铜矿能力, Acidithiobacillus caldus和Sulfobacillus acidophilus在浸出过程中起着重要的作用,pH 值和铜浸出率与群落结构相关性较高。     

Leaching of iron from kaolins by a spent fermentation liquor: Influence of temperature,pH, agitation and citric acid concentration

Summary The efficiency of a biological bleaching process on a highly contaminated iron oxides kaolin was analyzed. The bio-bleaching method consists of two steps: first, the fermentation of a chemically-defined medium byAspergillus niger leads to a spent liquor which, in a second step, is employed as leaching agent for kaolin. In the leaching process 43% of iron oxides was removed when the kaolin was treated at 60°C for 5 h and the whiteness index was increased to 67%. Extracellular enzymes were not responsible for leaching, which is basically due to organic acids produced during the fermentation.