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.     

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.     

Comparison of chalcopyrite bioleaching after different microbial enrichment in shake flasks

The bioleachings of chalcopyrite ore were compared after inoculating different cultures enriched from the original acid mine drainage sample. The results showed that the higher bioleaching performance was achieved for inoculation with the enrichment D (0.5 % S, 2 % iron and 1 % chalcopyrite) compared to other enrichment systems. The generated ferric precipitation during bioleaching had a key influence on the final copper extraction. After enrichment, higher ratio of iron-oxidizer and higher ratio of sulfur-oxidizer existed in enrichment B and C, respectively. These caused the different bioleaching behaviours from other systems. Maintaining a suitable equilibrium between iron- and sulfur-oxidizers is significant to decrease ferric precipitation or postpone its formation, finally prolong efficient bioleaching period and improve copper extraction.     

Optimization of staged bioleaching of low-grade chalcopyrite ore in the presence and absence of chloride in the irrigating lixiviant: ANFIS simulation

In this investigation, copper was bioleached from a low-grade chalcopyrite ore using a chloride-containing lixiviant. In this regard, firstly, the composition of the bacterial culture media was designed to control the cost in commercial application. The bacterial culture used in this process was acclimated to the presence of chloride in the lixiviant. Practically speaking, the modified culture helped the bio-heap-leaching system operate in the chloridic media. Compared to the copper recovery from the low-grade chalcopyrite by bioleaching in the absence of chloride, bioleaching in the presence of chloride resulted in improved copper recovery. The composition of the lixiviant used in this study was a modification with respect to the basal salts in 9 K medium to optimize the leaching process. When leaching the ore in columns, 76.81 % Cu (based on solid residues of bioleaching operation) was recovered by staged leaching with lixiviant containing 34.22 mM NaCl. The quantitative findings were supported by SEM/EDS observations, X-ray elemental mapping, and mineralogical analysis of the ore before and after leaching. Finally, Adaptive neuro-fuzzy inference system (ANFIS) was used to simulate the operational parameters affecting the bioleaching operation in chloride–sulfate system.     

中等嗜热细菌浸出黄铜矿过程中pH对群落结构的影响

为了优化浸出工艺,研究了pH对浸矿过程主要微生物种群结构的影响。用中度嗜热混合菌槽浸黄铜矿精矿,在不控制pH,控制pH为2．5及控制pH为1．2时,应用PCR-RFLP（限制性酶切片段长度多态性）方法对上述浸出条件下的细菌群落动态变化进行研究。结果表明,浸出体系只有两种微生物,一种为Acidithiobacillus Caldus,一种为Leptospirillum ferriphilum。pH对群落结构有明显影响。不控制pH时,浸出开始阶段At．caldus是优势种群,占群落的96％,随着浸出的进行,L．ferriphilum增多,在浸出后期代替At．caldus成为优势菌种,占69％。控制pH时,L．ferriphilum始终占主导地位,同时发现pH为2．5时At．caldus在群落中的丰度比pH为1．2时高。     

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。     

Modeling of growth and laccase production by Pycnoporus sanguineus

Production of extracellular laccase by the white-rot fungus Pycnoporus sanguineus was examined in batch submerged cultures in shake flasks, baffled shake flasks and a stirred tank bioreactor. The biomass growth in the various culture systems closely followed a logistic growth model. The production of laccase followed a Luedeking-Piret model. A modified Luedeking-Piret model incorporating logistic growth effectively described the consumption of glucose. Biomass productivity, enzyme productivity and substrate consumption were enhanced in baffled shake flasks relative to the cases for the conventional shake flasks. This was associated with improved oxygen transfer in the presence of the baffles. The best results were obtained in the stirred tank bioreactor. At 28 °C, pH 4.5, an agitation speed of 600 rpm and a dissolved oxygen concentration of ~25 % of air saturation, the laccase productivity in the bioreactor exceeded 19 U L^?1 days^?1, or 1.5-fold better than the best case for the baffled shake flask. The final concentration of the enzyme was about 325 U L^?1.     

Use of packed bed bioreactors application to ores bioleaching

Summary The behaviour of glass beads, silicagel and activated carbon particles as bacteria supports for using in backed bed bioreactor has been compared. No important difference was found. Additionally the performance of a bioreactor with glass beads was compared with that of a conventional percolating column in the bioleaching of a copper sulphide ore. Results showed higher copper extraction using the bioreactor.     

Tank bioleaching of copper from combined flotation concentrate and smelter dust

Bioleaching studies were conducted to evaluate the extraction of copper from combined flotation concentrate and smelter dust using two different dust-addition strategies, non-fractional (simultaneously with concentrate) and fractional (step-wise dust addition) in stirred tank reactors. The highest copper extraction obtained with the fractional dust addition was up to 94% while extraction using the non-fractional method leveled off at approximately 44%. Thus, an increased copper recovery of about 50% was achieved with the fractional dust-addition method. It seems that the main reason for increased copper recovery using fractional dust addition could be the control and prevention of chalcopyrite passivation (according to SEM/EDS, XRD, and quantitative mineralogy data). This leads to its improved dissolution.     

Column Bioleaching of Low-Grade Chalcopyritic Ore Using Moderate Thermophile Bacteria

Bacterially assisted heap leaching is an economical technology for treating low grade copper sulphides. In the present research, bioleaching of low grade chalcopyrite ore (1% chalcopyrite, and 3% pyrite) have been investigated using moderate thermophilic bacteria. The ore sample has low solubility in acid solution (about 5%). Experiments were carried out using column reactors and the effect of particle size (?12.7, ?19.07 and ?25.04 mm) and external addition of carbon dioxide to the induced air (10% v/v) have been investigated. Results have shown that the copper recovery increased with reducing particle size, and carbon dioxide addition improved bacterial activity and copper dissolution. In the optimum condition, i.e., particles finer than 12.07 mm and 10% (v/v) carbon dioxide addition, 69.68% of copper were extracted.     

Kinetic modeling and scale up of lipoic acid (LA) production from Saccharomyces cerevisiae in a stirred tank bioreactor

Scale up studies for production of lipoic acid (LA) from Saccharomyces cerevisiae have been reported in this paper for the first time. LA production in batch mode was carried out in a stirred tank bioreactor at varying agitation and aeration with maximum LA production of 512 mg/L obtained at 350 rpm and 25 % dissolved oxygen in batch culture conditions. Thus, LA production increased from 352 mg/L in shake flask to 512 mg/L in batch mode in a 5 L stirred tank bioreactor. Biomass production under these conditions was mathematically explained using logistic equation and data obtained for LA production and substrate utilization were successfully fitted using Luedeking–Piret and Mercier’s models. The kinetic studies showed LA production to be growth associated. Further enhancement of LA production was carried out using fed-batch (variable volume) and semi-continuous modes of fermentation. Semi-continuous fermentation with three feeding cycles of sucrose effectively increased the production of LA from 512 to 725 mg/L.     

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 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.     

Influence of oxygen transfer on <Emphasis Type="Italic">Pseudomonas putida</Emphasis> effects on growth rate and biodesulfurization capacity

The growth rate and desulfurization capacity accumulated by the cells during the growth of Pseudomonas putida KTH2 under different oxygen transfer conditions in a stirred and sparged tank bioreactor have been studied. Hydrodynamic conditions were changed using different agitation conditions. During the culture, several magnitudes associated to growth, such as the specific growth rate, the dissolved oxygen concentration and the carbon source consumption have been measured. Experimental results indicate that cultures are influenced by the fluid dynamic conditions into the bioreactor. An increase in the stirrer speed from 400 to 700 rpm has a positive influence on the cell growth rate. Nevertheless, the increase of agitation from 700 to 2000 rpm hardly has any influence on the growth rate. The effect of fluid dynamics on the cells development of the biodesulfurization (BDS) capacity of the cells during growth is different. The activities of the intracellular enzymes involved in the 4S pathway change with dissolved oxygen concentration. The enzyme activities have been evaluated in cells at several growth time and different hydrodynamic conditions. An increase of the agitation from 100 to 300 rpm has a positive influence on the development of the overall BDS capacity of the cells during growth. This capacity shows a decrease for higher stirrer speeds and the activity of the enzymes monooxygenases DszC and DszA decreases dramatically. The highest value of the activity of DszB enzyme was obtained with cells cultured at 100 rpm, while this activity decreases when the stirrer speed was increased higher than this value.     

Control of the redox potential by oxygen limitation improves bacterial leaching of chalcopyrite

Shake flask and stirred tank bioleaching experiments showed that the dissolution of chalcopyrite is inhibited by ferric ion concentrations as low as 200 mg L(-1) and redox potentials >420 mV (vs. Ag/AgCl). Chemical leaching of chalcopyrite (4% suspension, surface area 2.3 m2 g(-1)) was enhanced fourfold in the presence of 0.1 M ferrous sulphate compared with 0.1 M ferric sulphate. A computer-controlled reactor was designed to function as a "potentiostat"-bioreactor by arresting the air supply to the reactor when the redox potential in solution was greater than a designated setpoint. Leaching at a low, constant redox potential (380 mV vs. Ag/AgCl) achieved final copper recoveries of 52%-61%, which was twice that achieved with a continuous supply of oxygen (<30% extraction). The bacterial populations were observed to continue growing under oxygen limitation but in a controlled manner that was found to improve chalcopyrite dissolution. As the control mechanism is easily established and is likely to decrease production cost, the use of this technology may find application in industry.     

Isolation and characterization of Ferroplasma thermophilum sp. nov., a novel extremely acidophilic, moderately thermophilic archaeon and its role in bioleaching of chalcopyrite

Aims:  To isolate Ferroplasma thermophilum L1^T from a low pH environment and to understand its role in bioleaching of chalcopyrite.
Methods and Results:  Using serial dilution method, a moderately thermophilic and acidophilic ferrous iron-oxidizing archaeon, named L1^T, was isolated from a chalcopyrite-leaching bioreactor. The morphological, biochemical and physiological characteristics of strain L1^T and its role in bioleaching of chalcopyrite were studied. Strain L1^T was a nonmotile coccus that lacked cell wall. Strain L1^T had a temperature optimum of 45°C and the optimum pH for growth was 1·0. Strain L1^T was capable of chemomixotrophic growth on ferrous iron and yeast extract. Results of fatty acid analysis, DNA–DNA hybridization, G+C content, and analysis based on 16S rRNA gene sequence indicated that strain L1^T should be grouped in the genus Ferroplasma , and represented a new species, Ferroplasma thermophilum . Ferroplasma thermophilum in combination with Acidithiobacillus caldus and Leptospirillum ferriphilum could improve the copper dissolution in bioleaching of chalcopyrite.
Conclusions:  A novel extremely acidophilic, moderately thermophilic archaeon isolated from a bioleaching reactor has been identified as F. thermophilum that played an important role in bioleaching of chalcopyrite at low pH.
Significance and Impact of the Study:  This study contributes to understand the characteristics of F. thermophilum L1^T and its role in bioleaching of sulfide ores.     

Production of hepatitis B core antigen in a stirred tank bioreactor: The influence of temperature and agitation

The influence of temperature and agitation on the growth ofEscherichia coli expressing hepatitis B core antigen (HBcAg) in stirred tank bioreactor were investigated. The highest specific growth rate forE. coli (0.844 h⁻¹) was achieved at a temperature of 37°C and an agitation speed of 250 rpm. The activation energy for the growth of theE. coli strain W3110IQ in the stirred tank bioreactor was estimated to be 11 kcal/mol. The highest protein yield was achieved at a temperature of 44°C and an agitation speed of 250 rpm. The relative protein concentration at 44°C is 30 and 6% higher compared to that at 30 and 37°C, respectively.     

Selective leaching of zinc from copper-zinc concentrate

Biooxidation of copper-zinc concentrate with the use of consortia of mesophilic and moderately thermophilic acidophilic chemolithotrophic microorganisms was studied. Pyrrhotite, sphalerite, and chalcopyrite were the main sulfide minerals of the concentrate. The possibility in principal of complete selective leaching of zinc from sulfide concentrate coupled with minimal recovery of copper (less than 20%) was demonstrated. Selective leaching of zinc could be caused by galvanic interactions between minerals of the concentrate during the biooxidation. The results can be used as the basis for the development of the technologies for production of grade copper concentrate not containing zinc from sulfide copper-zinc concentrate obtained from refractory ores.     

Bioleaching of Different Pyrites and Sphalerite in the Presence of Graphite

In this research work the effect of pyrite type and graphite on the pyrite and sphalerite dissolution rate was investigated, using a mixed culture of moderately thermophilic microorganisms. Two samples of: fine granular surface pyrite and crystalline euhedral pyrite were prepared from black shale and copper porphyry deposits, respectively. Results indicated that granular surface pyrite dissolution rate and Fe(III) concentration are significantly higher than those of crystalline euhedral pyrite. As a result, higher Zn extraction improvement was observed in the presence of granular surface pyrite. Addition of graphite to the experiments enhanced the microorganism population in leaching solution and accelerated crystalline euhedral pyrite and sphalerite bioleaching rate. Using graphite in the experiments resulted in catalytic effect of crystalline pyrite and sphalerite, in which, with graphite, the Fe extraction increased from 25.57% to 59.84% and Zn extraction was improved from 22.17% to 53.37%, for 28 days of bioleaching. The catalytic effect of graphite on crystalline euhedral pyrite and also sphalerite bioleaching could be attributed to the rising of the microorganism population or galvanic interaction in which graphite acted as the cathode and accelerated the anodic dissolution of pyrite and sphalerite.     

Microbiological Redox Potential Control to Improve the Efficiency of Chalcopyrite Bioleaching

The effect of controlling the redox potential (E_h) on chalcopyrite bioleaching kinetics was studied as a new aspect of redox control during chalcopyrite bioleaching, and its mechanism was investigated by employing the “normalized” solution redox potential (E_normal) and the reaction kinetics model. Different E_h ranges were established by use of different acidophiles (Sulfobacillus acidophilus YTF1; Sulfobacillus sibiricus N1; Acidimicrobium ferrooxidans ICP; Acidiplasma sp. Fv-AP). Cu dissolution was very susceptible to real-time change in E_h during the reaction. It was found that efficiency of bioleaching of chalcopyrite can be effectively evaluated on the basis of E_normal, since it is normalized for real-time fluctuations of concentrations of major metal solutes during bioleaching. For steady Cu solubilization during bioleaching at a maximum rate, it was important to maintain a redox potential range of 0 ≤ E_normal ≤ 1 (?0.35 mV optimal) at the mineral surface by employing a “weak” ion-oxidizer. This led to a copper recovery of > 75%. At higher E_normal levels (E_normal > 1 by “strong” microbial Fe²⁺ oxidation), Cu solubilization was slowed by diffusion through the product film at the mineral surface (< 50% Cu recovery) caused by low reactivity of the chalcopyrite and by secondary passivation of the chalcopyrite surface, mainly by jarosite.