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.     

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.     

Continuous Bioleaching of Chalcopyritic Concentrate at High Pulp Density

The main objective of the present study was to investigate the continuous bioleaching of chalcopyrite concentrate at a high pulp density by moderate thermophilic microorganisms. Using a flotation concentrate containing 46% chalcopyrite and 23% pyrite, bioleaching tests were carried out at a high pulp density (15%) and temperature of 47°C using a setup consisting of three continuous stirred tank bioreactors in series. A two-level full factorial design of experiments was used to assess the effects of residence time, particle size and acidity of the leaching solution on the copper recovery. From the results of these tests, we concluded that under the best process conditions (d₈₀ = 30 μm, T = 47°C, and acidity of 130 kg/ton) more than 54% of copper was extracted from the concentrate after 7 days. Also, the concentration of copper in the final solution was higher than 20 g/L.     

Chemical leaching of copper-zinc concentrate with ferric iron biosolution

The process of leaching of copper-zinc concentrate with a solution containing biogenic iron, which is a product of the metabolism of iron-oxidizing microorganisms, was studied. The dependence of leaching rate of metals on temperature and pH was determined. It was shown that up to 98% of zinc and 70% of iron could be removed from the concentrate, while up to 7 and 4 g/L of zinc and copper, respectively, were accumulated in the liquid phase, which was sufficient for metal recovery. It was established that a copper concentrate with copper content up to 16% and only 0.5% of zinc could be obtained after chemical leaching for 340 min at 80°C.     

Bioleaching of a Complex Co-Ni-Cu Sulfide Flotation Concentrate by Bacillus megaterium QM B1551 at Neutral pH

Bioleaching of sulfide minerals at neutral pH has been rarely reported. In this study, a bacterium, Bacillus megaterium QM B1551, was isolated from Jinchuan sulfide tailings and used to leach a complex sulfide flotation concentrate for the extraction of Co²⁺, Ni²⁺ and Cu²⁺ at near neutral pH. A total of 38.2% Co, 44.7% Ni and 3.6% Cu were extracted from the sulfide concentrate in 5 days with an initial pH of 6. An enhanced Co²⁺, Ni²⁺ and Cu²⁺ extraction extent was achieved by first bioleaching the concentrate with Bacillus megaterium QM B1551 at 35°C and then followed by chemical leaching with 4 M sulfuric acid at 90°C. As a result, a total of 60.7% Co²⁺, 76.3% Ni²⁺ and 39.8% Cu²⁺ were extracted. On an industrial scale, the profits from the metal recovery by such a combined leaching procedure are optimum if considering the cost-benefit ratio.     

Selective extraction of metals from zinc concentrate by association of chemolithotrophic bacteria

Ability for selective extraction of copper and zinc from zinc concentrate using association of chemolithotrophic bacteria was investigated. In the presence of bacterial association, the rate of leaching of zinc, copper, and iron was increased 3-fold, 4–5-fold, and 2-fold, respectively. The results indicate the maximum dissolution rate for zinc, then followed by copperand iron. It was revealed that addition of Fe³⁺ 2 g/l resulted in reduction of iron leaching and in 3-fold increase of leaching rate of copper at constant dissolution rate of mineral zinc. It is suggested that the intensification of copper leaching is connected with the activity of sulfur-oxidizing bacteria able to activate the mineral surface via elimination of passivation layer of elemental sulfur. It was concluded that sulfur-oxidizing bacteria play a significant role in copper leaching from zinc concentrate. A unique strain of mesophile sulfur-oxidizing bacteria was isolated from leaching pulp of zinc concentrate; in the perspective, it may serve as efficient candidate for performing of selective extraction of copper from zinc concentrate.     

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.     

Characterization of iron- and sulphide mineral-oxidizing moderately thermophilic acidophilic bacteria from an Indonesian auto-heating copper mine waste heap and a deep South African gold mine

Iron- and chalcopyrite-oxidizing enrichment cultures were obtained at 50°C from acidic, high-temperature, copper/gold mine environments in Indonesia and South Africa. Over 90% copper yield was obtained from chalcopyrite concentrate with the Indonesian enrichment in 3 months with 2% solids concentration, when pH was maintained at around 2. Neither addition of silver cations nor an enhanced nutrient concentration influenced chalcopyrite leaching. Excision and sequencing of bands from denaturing gradient gel electrophoresis of the amplified partial 16S rRNA gene showed that the enrichment cultures from different environments in South Africa and Indonesia were very simple, and similar. Chalcopyrite concentrate supported a simpler and different community than Fe²⁺. The members of the enrichment cultures were closely related to Sulfobacillus yellowstonensis and Sulfobacillus acidophilus.     

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.     

Effects of copper and other metals on fertilization,embryo development,larval survival and settlement of the polychaete Nereis (Neanthes) virens

Summary

Nectochaete larvae of the ecologically and economically important ragworm, Nereis virens, were exposed to cadmium, chromium, copper, lead and zinc dissolved in seawater to nominal concentrations ranging from 0 to 5000 μg l^?1. Copper was the most toxic (mean LC50 of 76.5 μg l^?1 ± 95% CI 73.8–79.2 after 96 h exposure) and so was used for subsequent experiments. Exposure of gametes to greater than 500 μg l^?1 copper for 2 or 4 h at 10°C prior to fertilization, or a 10 min exposure during fertilization, significantly reduced embryo developmental success. The effect of copper on larval settlement was also assessed using sediment spiked to a range of concentrations (0, 50, 250, 500, 1000 mg kg!1 dry weight). Significantly fewer larvae were found in sediment of $250 mg kg!1 in comparison to the control or the 50 mg kg!1 treatment. Assessment of living larvae also confirmed a significant reduction in settlement, but in all treatments compared to the control, although the number of dead larvae also increased as the concentrations increased. These effects may have important implications for reproductive success and recruitment of N. virens to polluted sediments.     

Leaching of copper ores by chemoorganotrophic microorganisms

Summary Some copper-leaching microorganisms were isolated from weathered rock material of old copper deposits. Among these the strain Bacillus sp. L 1 was able to solubilize completely the copper contained in low-grade ore material under optimal conditions. The most suitable leaching solution was sulphite waste liquor from the paper industry. Decreasing effectiveness of metal recovery was observed with increasing particle size and increasing solid-liquid ratio. In silver leaching, a maximum was measured after 3 days followed by a rapid decrease. Possible technical uses of leaching processes are discussed. Offprint requests to: G. Straube     

Relationship between bioleaching performance,bacterial community structure and mineralogy in the bioleaching of a copper concentrate in stirred-tank reactors

During the Bioshale European project, a techno-economic study of the bioleaching of a copper concentrate originating from a black shale ore was carried out. This concentrate is a multi-mineral resource in which the copper sulphides are mainly chalcocite, covellite, bornite and chalcopyrite. The experiments undertaken to produce the techno-economic data were also an opportunity to carry out more fundamental research. The objective of this work was to combine the results of the bioleaching experiments, in terms of copper recovery, with the results of bacterial community monitoring and mineralogy residue analysis. Batch and continuous bioleaching tests were carried out with 10% solids, at 42 °C and with a pH between 1.2 and 1.6. Final copper recovery was higher in batch cultures than in continuous mode (>95% vs. 91%). Mineralogical analysis showed that the limiting factor for copper recovery was incomplete chalcopyrite dissolution in both cases. However, chalcopyrite was even less dissolved in continuous conditions. This was also related to a variation in bacterial community structure. The population in all tests was composed of Acidithiobacillus caldus, Leptospirillum ferriphilum and one or two species of Sulfobacillus (Sulfobacillus thermosulfidooxidans and sometimes Sulfobacillus benefaciens), but Sulfobacillus and more generally sulphur oxidizers were more represented in batch mode. It was proposed that due to their capacity to reduce inorganic compounds, sulphur oxidizers may be efficient in limiting chalcopyrite surface hindering. It may help to better dissolve this mineral and reach a better copper recovery.     

Process engineering aspects of the bioleaching of copper ores

The bioleaching of minerals is a complex process that is affected by a number of biological, mineralogical, electrochemical and engineering factors. This work presents and discusses the most significant process engineering aspects involved in the bacterial leaching of copper ores, i.e. bacterial population, type of mineral and particle size, nutrients and inhibitors, oxygen and carbon dioxide, temperature and pH, leaching kinetics and operation mode.It is concluded that more work is needed in this area in order to gain a deeper insight in the many factors that govern this process. This would allow to significantly improve its overall productivity.List of Symbols C _L kg/m³ dissolved oxygen concentration - C ^* kg/m³ equilibrium oxygen concentration - d, e, f, g % percentage of C, H, O and N in the cell - D m impeller diameter - K consistency index - K _S, K₁, K_c constants - k _La h^–1 volumetric oxygen transfer coefficient - M _b mol/kg biomass apparent molecular weight - N s^–1 rotation frequency - n behavior index - P kg/m³ ungassed agitation power, product concentration - P _g kW/m³ gassed agitation power - p % pulp density - Q m³/h air flow rate - S kg/m³ limiting substrate concentration - W kg/(m³ · h) mass transfer rate per unit volume - X cells/cm³ biomass concentration - Y _o g cells/g Fe oxygen cell yield - Y _x g cells/g Fe substrate cell yield - h^–1 specific growth rate - _m h^–1 maximum specific growth rate     

Effects of copper on algal communities at different current velocities

This study examines the influence of current velocity in the toxiceffect of copper in diatom-dominated biofilms grown in artificial channels.Effects on community structure, algal biomass and photosynthesis (carbonincorporation) caused by 15 g L^–1 of copperwere tested at contrasting (1 and 15 cm s^–1)velocities. Moreover, a possible threshold on the effect of copper on algalbiomass and photosynthesis related to current velocity was examined by usingprogressively increasing current velocity (1 to 50 cms^–1) at 15 g L^–1 Cu.Chlorophyll-a decreased ca. 50% as a result of addition of15 g L^–1 Cu. Chlorophyll decrease occurredearlier at 15 cm s^–1 than at 1 cms^–1 when adding 15 g L^–1Cu. Copper also caused a remarkable decrease in carbon incorporation(from 30 to ca. 50%), which was produced earlier at 15 cms^–1 (three days) than at 1 cms^–1 (seven days). Some taxa were affected by thecombination of copper and current velocity. Both Achnanthesminutissima and Stigeoclonium tenue becomedominant at 15 cm s^–1 in the presence of copper.Significant inhibition of algal growth in 15 g L^–1Cu occurred at low (1 cm s^–1) and highvelocities (50 cm s^–1), but not at intermediatevelocity (20 cm s^–1). The experiments indicatethat current velocity triggers the effect that copper has on diatom-dominatedbiofilms, and that the effect is more remarkable at low and high than atintermediate current velocities.     

Physiological background for using freshwater mussels in monitoring copper and lead pollution

In studying the effect of copper (10 ± 0.57 µg Cu l^–1 and 100 ± 3.01 µg Cu l^–1) and lead (50 ± 1.12 µg Pb l^–1 and 500 ± 12.5 µg Pb l^–1) on the filtration activity of Anodonta cygnea L. it was found that both heavy metals resulted in significant shortening of the active periods, but little change occurred in the length of the rest periods. The concentrations of copper and lead were measured in the gill, foot, mantle, adductor muscle and kidney for 840 hours of exposure to 10.9 ± 5 µg Cu l^–1 and 57.0 ± 19 µg Pb l^–1 as well as during subsequent depuration. Uptake was observed after 72 hours of exposure. The highest copper concentration (59.1 ± 16.2 µg Cu g^–1) was measured at 672 h in the mantle, and the highest lead value (143 ± 26.1 µg Pb^–1) was obtained in the kidney. Depuration of copper was fastest from the foot, and from the adductor muscle for lead. The gill had the longest half-depuration time (> 840 h for copper and > 672 h for lead).     

Identification of the dominant bacterium of two-stage biooxidation of gold-arsenic concentrate

In the process of biooxidation at 39°C in a continuous mode of the gold-arsenic concentrate from the Olympiadinskoe deposit, which was pretreated by chemical leaching with ferric ions, by a microbial association from the BIO department reactors of the Polyus gold mining company, a bacterial culture designated as strain HT-4 was isolated. The bacterium was a spore-forming rod 0.5–0.6 × 1.4–2.0 μm with a flagellum. The optimal temperature for growth and Fe²⁺ oxidation was 55°C. The strain grew in the pH range from 1.21 to 2.10 with the optimum at pH 1.6. The organism was incapable of lithotrophic and organotrophic growth. It grew mixotrophically by Fe²⁺ oxidation in the presence of 0.02% yeast extract. The DNA G+C base content was 48.6 mol %. Based on comparative phylogenetic analysis of 1472-bp nucleotide sequences of 16S rRNA genes, strain HT-4 was classified as Sulfobacillus thermosulfidooxidans. Analysis by pulse-field gel electrophoresis revealed a unique profile of the NotI fragments of the chromosomal DNA. These results demonstrate the strain and species diversity of sulfobacilli in microbial associations involved in biooxidation of concentrates in different technological conditions. The strain “S. olympiadicus S-5” dominated in the process of biooxidation of original concentrate not treated with ferric iron, while S. thermosulfidooxidans HT-4 was predominant in biooxidation of the chemically leached concentrate.     

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.     

Plant uptake and leaching of copper during EDTA-enhanced phytoremediation of repacked and undisturbed soil

EDTA-enhanced phytoremediation of copper contaminated soil was evaluated. Up to 740 g g^–1 of Na₂H₂ EDTA in solution was added to repacked soil columns, and intact cores of a sandy loam of volcanic origin, that was growing Agrostis tenuis. The soil contained up to 400 g g^–1 of copper due to a history of fungicide spraying. EDTA application increased the herbage copper concentration of the grass growing in repacked soil from 30 to 300 g g^–1, but the same application to an intact core only brought about an increase from 10 to 60 g g^–1. More copper accumulated in the herbage when the EDTA was applied in numerous small doses than in just one or two larger amounts. Calculation of the concentration of copper in the water taken up by the grass revealed this to be two orders of magnitude lower than that in the soil solution. As a result of the EDTA applications, about 100 times more copper was leached than was taken up by the herbage. This means that a strategy for managing leaching losses needs to be part of any plan for EDTA-enhanced phytoremediation.     

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.     

Bioregeneration of Leaching Solutions during Two-Step Processing of Copper-Zinc Concentrate

A comparative study of the oxidation of ferrous iron ions by various cultures of acidophilic chemolithotrophic microorganisms in solutions obtained after ferric leaching of copper-zinc concentrate at 80°C has been carried out. It was shown that the use of a moderately thermophilic culture for bioregeneration of leaching solutions was preferable. At the same time, the oxidation rate of Fe²⁺ ions reached 0.88 g/(L h), or 21.1 g/(L day). We propose that the activity of the moderately thermophilic culture was due to the presence of the mixotrophic bacteria Sulfobacillus spp., which used organic products of the microbial lysis for their growth. These products were formed during high-temperature ferric leaching of the copper-zinc concentrate with the biosolution.