Comparison of bioleaching of a sulfidic copper ore (chalcopyrite) in column percolators and in stirred-tank bioreactors including microbial community analysis.

Chalcopyrite is the most abundant Cu-sulfide and economically the most important copper mineral in the world. It is known to be recalcitrant in hydrometallurgical processing and therefore chalcopyrite bioleaching has been thoroughly studied for improvement of processing. In this study, the microbial diversity in 22 samples from the Sarcheshmeh copper mine in Iran was investigated via 16S rRNA gene sequencing. In total, 1063 species were recognized after metagenomic analysis including the ferrous iron- and sulfur-oxidizing acidophilic genera Acidithiobacillus, Leptospirillum, Sulfobacillus and Ferroplasma. Mesophilic as well as moderately thermophilic acidophilic ferrous iron- and sulfur-oxidizing microorganisms were enriched from these samples and bioleaching was studied in shake flask experiments using a chalcopyrite-containing ore sample from the same mine. These enrichment cultures were further used as inoculum for bioleaching experiments in percolation columns for simulating heap bioleaching. Addition of 100 mM NaCl to the bioleaching medium was assessed to improve the dissolution rate of chalcopyrite. For comparison, bioleaching in stirred tank reactors with a defined microbial consortium was carried out as well. While just maximal 32% copper could be extracted in the flask bioleaching experiments, 73% and 76% of copper recovery was recorded after 30 and 10 days bioleaching in columns and bioreactors, respectively. Based on the results, both, the application of moderately thermophilic acidophilic bacteria in stirred tank bioreactors, and natural enrichment cultures of mesoacidophiles, with addition of 100 mM NaCl in column percolators with agglomerated ore allowed for a robust chalcopyrite dissolution and copper recovery from Sarcheshmeh copper ore via bioleaching.

La amplia distribución de un microorganismo termoacidófilo en el mineral de una mina cuprífera a temperatura ambiente y en condición ácida, y su importancia en la biolixiviación del concentrado de calcopirita / The wide distribution of an extremely thermoacidophilic microorganism in the copper mine at ambient temperature and under acidic condition and its significance in bioleaching of a chalcopyrite concentrate

Thermoacidophiles can exist in a state of dormancy both in moderate temperatures and even in cold conditions in heap leaching. Sulphide mineral ores such as chalcopyrite produce sulfuric acid when exposed to the air and water. The produced sulfuric acid leads to the decrease of pH and exothermic reactions in heap leaching causing the temperature to increase up to 55 °C and the activation of thermoacidophilic microorganisms. The aim of the present study was to isolate indigenous extreme thermoacidophilic microorganisms at ambient temperature from Sarcheshmeh Copper Complex, to adapt them to the high pulp density of a chalcopyrite concentrate, and to determine their efficiency in chalcopyrite bioleaching in order to recover copper. In this study samples were collected at ambient temperature from Sarcheshmeh Copper Complex in Iran. Mixed samples were inoculated into the culture medium for enrichment of the microorganisms. Pure cultures from these enrichments were obtained by subculture of liquid culture to solid media. Morphological observation was performed under the scanning electron microscope. Isolates were adapted to 30% (w/v) pulp density. For the bioleaching test, the experiments were designed with DX7 software. Bioleaching experiments were carried out in Erlenmeyer flasks and a stirred tank reactor. The highest copper recovery in Erlenmeyer flasks was 39.46% with pulp 15%, inoculums 20%, size particle 90 pm and 160 rpm. The lowest recovery was 3.81% with pulp 20%, inoculums 20%, size particle 40 pm and 140 rpm after 28 days. In the reactor, copper recovery was 32.38%. Bioleaching residues were analyzed by the X-ray diffraction (XRD) method. The results showed no jarosite (KFe3(SO4)2(OH)6) had formed in the bioleaching experiments. It seems that the antagonistic reactions among various species and a great number of planktonic cells in Erlenmeyer flasks and the stirred tank reactor are the reasons for the low recovery of copper in our study.

Los microorganismos termoacidófilos pueden estar en estado latente tanto a temperatura moderada como baja, en lixiviación en pilas. Los minerales sulfurosos, como la calcopirita, producen ácido sulfúrico cuando se exponen al aire y al agua. El ácido sulfúrico producido conduce a la disminución del pH y a reacciones exotérmicas durante la lixiviación en pilas, lo que hace que la temperatura aumente hasta 55 °C y se activen los microorganismos termoacidófilos. El objetivo del presente estudio fue aislar del complejo de cobre Sarchesh-meh (Irán) microorganismos termoacidófilos extremos que proliferan a temperatura ambiente e investigar su adaptación a la alta densidad de pulpa del concentrado de calcopirita, así como su eficiencia para biolixiviarese mineral, con el objeto de recuperar el cobre. Se recogieron muestras a temperatura ambiente del citado complejo, y luego muestras mixtas se inocularon en un medio de cultivo de enriquecimiento. A partir de estos enriquecimientos, mediante el subcultivo del cultivo líquido a medio sólido, se obtuvieron cultivos puros. La observación morfológica se realizó bajo microscopio electrónico de barrido. Los aislados estaban adaptados al 30% p/v de densidad de pulpa. Para la prueba de biolixiviación, los experimentos fueron diseñados con el software DX7. Los experimentos de biolixiviación se llevaron a cabo en Erlenmeyers y en un reactor tanque con agitación. La mayor recuperación de cobre en los Erlenmeyers fue del 39,46% y se obtuvo con la pulpa al 15%, un inóculo del 20%, un tamaño de partícula de 90 µm y una agitación de 160 rpm. La menor recuperación fue del 3,81% y se obtuvo con la pulpa al 20%, un inóculo del 20%, un tamaño de partícula de 40 µm y una agitación de 140 rpm, después 28 días. En el reactor, la recuperación del cobre fue del 32,38%. El análisis de difracción de rayos X (XRD) no mostró que se formara jarosita (KFe3-#91;SO4-#93;2-#91;OH-#93;6) en los experimentos de biolixiviación. Dicha técnica sirve para determinar la estructura cristalina de una sustancia desconocida. Al parecer, las reacciones antagónicas entre las diversas especies y el mayor número de células planctónicas en los Erlenmeyers y en el reactor fueron las causas de la baja recuperación de cobre observada en este estudio.

The wide distribution of an extremely thermoacidophilic microorganism in the copper mine at ambient temperature and under acidic condition and its significance in bioleaching of a chalcopyrite concentrate.

Thermoacidophiles can exist in a state of dormancy both in moderate temperatures and even in cold conditions in heap leaching. Sulphide mineral ores such as chalcopyrite produce sulfuric acid when exposed to the air and water. The produced sulfuric acid leads to the decrease of pH and exothermic reactions in heap leaching causing the temperature to increase up to 55°C and the activation of thermoacidophilic microorganisms. The aim of the present study was to isolate indigenous extreme thermoacidophilic microorganisms at ambient temperature from Sarcheshmeh Copper Complex, to adapt them to the high pulp density of a chalcopyrite concentrate, and to determine their efficiency in chalcopyrite bioleaching in order to recover copper. In this study samples were collected at ambient temperature from Sarcheshmeh Copper Complex in Iran. Mixed samples were inoculated into the culture medium for enrichment of the microorganisms. Pure cultures from these enrichments were obtained by subculture of liquid culture to solid media. Morphological observation was performed under the scanning electron microscope. Isolates were adapted to 30% (w/v) pulp density. For the bioleaching test, the experiments were designed with DX7 software. Bioleaching experiments were carried out in Erlenmeyer flasks and a stirred tank reactor. The highest copper recovery in Erlenmeyer flasks was 39.46% with pulp 15%, inoculums 20%, size particle 90µm and 160rpm. The lowest recovery was 3.81% with pulp 20%, inoculums 20%, size particle 40µm and 140rpm after 28 days. In the reactor, copper recovery was 32.38%. Bioleaching residues were analyzed by the X-ray diffraction (XRD) method. The results showed no jarosite (KFe3(SO4)2(OH)6) had formed in the bioleaching experiments. It seems that the antagonistic reactions among various species and a great number of planktonic cells in Erlenmeyer flasks and the stirred tank reactor are the reasons for the low recovery of copper in our study.

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.

Bio-processing of copper from combined smelter dust and flotation concentrate: a comparative study on the stirred tank and airlift reactors.

To scrutinize the influence of the design and type of the bioreactors on the bioleaching efficiency, the bioleaching were evaluated in a batch airlift and a batch stirred tank bioreactors with mixed mesophilic and mixed moderately thermophilic bacteria. According to the results, maximum copper recoveries were achieved using the cultures in the stirred tank bioreactors. It is worth noting that the main phase of the flotation concentrate was chalcopyrite (as a primary sulphide), but the smelter dust mainly contained secondary copper sulphides such as Cu(2)S, CuS, and Cu(5)FeS(4).Under optimum conditions, copper dissolution from the combined flotation concentrate and smelter dust (as an environmental hazard) reached 94.50% in the STR, and 88.02% in the airlift reactor with moderately thermophilic, after 23 days. Also, copper extractions calculated for the bioleaching using mesophilic bacteria were 48.73% and 37.19% in the STR (stirred tank reactor) and the airlift bioreactor, respectively. In addition, the SEM/EDS, XRD, chemical, and mineralogical analyses and studies confirmed the above results.