A case in support of implementing innovative bio-processes in the metal mining industry.

The metal mining industry faces many large challenges in future years, among which is the increasing need to process low-grade ores as accessible higher grade ores become depleted. This is against a backdrop of increasing global demands for base and precious metals, and rare earth elements. Typically about 99% of solid material hauled to, and ground at, the land surface currently ends up as waste (rock dumps and mineral tailings). Exposure of these to air and water frequently leads to the formation of acidic, metal-contaminated run-off waters, referred to as acid mine drainage, which constitutes a severe threat to the environment. Formation of acid drainage is a natural phenomenon involving various species of lithotrophic (literally 'rock-eating') bacteria and archaea, which oxidize reduced forms of iron and/or sulfur. However, other microorganisms that reduce inorganic sulfur compounds can essentially reverse this process. These microorganisms can be applied on industrial scale to precipitate metals from industrial mineral leachates and acid mine drainage streams, resulting in a net improvement in metal recovery, while minimizing the amounts of leachable metals to the tailings storage dams. Here, we advocate that more extensive exploitation of microorganisms in metal mining operations could be an important way to green up the industry, reducing environmental risks and improving the efficiency and the economy of metal recovery.

Continuous bioscorodite crystallization in CSTRs for arsenic removal and disposal.

In CSTRs, ferrous iron was biologically oxidized followed by crystallization of scorodite (FeAsO(4)·2H(2)O) at pH 1.2 and 72 °C. The CSTRs were fed with 2.8 g L(-1) arsenate and 2.4 g L(-1) ferrous and operated at an HRT of 40 h, without seed addition or crystal recirculation. Both oxidation and crystallization were stable for periods up to 200 days. The arsenic removal efficiency was higher than 99% at feed Fe/As molar ratios between 1 and 2, resulting in effluents with 29 ± 18 mg As L(-1). Arsenic removal decreased to 40% at feed Fe/As molar ratios between 2 and 5. Microorganisms were not affected by arsenic concentrations up to 2.8 g As(5+) L(-1). The bioscorodite solid yield was 3.2 g/g arsenic removed. Bioscorodite crystals precipitated as aggregates, causing scaling on the glass wall of the reactor. The observed morphology through SE microscopy of the precipitates appeared amorphous but XRD analysis confirmed that these were crystalline scorodite. Arsenic leaching of bioscorodite was 0.4 mg L(-1) after 100 days under TCLP conditions, but when jarosite had been co-precipitated leaching was higher at 0.8 g L(-1). The robustness of the continuous process, the high removal efficiency and the very low arsenic leaching rates from bioscorodite sludge make the process very suitable for arsenic removal and disposal.

Kinetics of ferrous iron oxidation by batch and continuous cultures of thermoacidophilic Archaea at extremely low pH of 1.1-1.3.

The extreme acid conditions required for scorodite (FeAsO4·2H2O) biomineralization (pH below 1.3) are suboptimal for growth of most thermoacidophilic Archaea. With the objective to develop a continuous process suitable for biomineral production, this research focuses on growth kinetics of thermoacidophilic Archaea at low pH conditions. Ferrous iron oxidation rates were determined in batch-cultures at pH 1.3 and a temperature of 75°C for Acidianus sulfidivorans, Metallosphaera prunea and a mixed Sulfolobus culture. Ferrous iron and CO2 in air were added as sole energy and carbon source. The highest growth rate (0.066 h⁻¹) was found with the mixed Sulfolobus culture. Therefore, this culture was selected for further experiments. Growth was not stimulated by increase of the CO2 concentration or by addition of sulphur as an additional energy source. In a CSTR operated at the suboptimal pH of 1.1, the maximum specific growth rate of the mixed culture was 0.022 h⁻¹, with ferrous iron oxidation rates of 1.5 g L⁻¹ d⁻¹. Compared to pH 1.3, growth rates were strongly reduced but the ferrous iron oxidation rate remained unaffected. Influent ferrous iron concentrations above 6 g L⁻¹ caused instability of Fe²âº oxidation, probably due to product (Fe³âº) inhibition. Ferric-containing, nano-sized precipitates of K-jarosite were found on the cell surface. Continuous cultivation stimulated the formation of an exopolysaccharide-like substance. This indicates that biofilm formation may provide a means of biomass retention. Our findings showed that stable continuous cultivation of a mixed iron-oxidizing culture is feasible at the extreme conditions required for continuous biomineral formation.

Biogenic scorodite crystallization by Acidianus sulfidivorans for arsenic removal.

Scorodite is an arsenic mineral with the chemical formula FeAsO(4)*2H(2)O. It is the most common natural arsenate associated with arsenic-bearing ore deposits. In the present study we show that the thermoacidophilic iron-oxidizing archaeon Acidianus sulfidivorans is able to precipitate scorodite in the absence of any primary minerals or seed crystals, when grown on 0.7 g L(-1) ferrous iron (Fe(2+)) at 80 degrees C and pH 1 in the presence of 1.9 g L(-1) arsenate (H(3)AsO(4)). The simultaneous biologically induced crystallization of ferric iron (Fe(3+)) and arsenic to scorodite prevented accumulation of ferric iron. As a result, crystal growth was favored over primary nucleation which resulted in the formation of highly crystalline biogenic scorodite very similar to the mineral scorodite. Because mineral scorodite has a low water solubility and high chemical stability, scorodite crystallization may form the basis for a novel method for immobilization of arsenic from contaminated waters with high arsenic concentrations.