Bulk flotation followed by selective leaching with biogenic ferric iron is a promising solution for eco-friendly processing of complex sulfidic ores.

The development of cost-effective environmentally friendly technologies is of current importance for the intensification of metal recovery. Here, we propose a new direction in the use of a two-step process for the treatment of complex sulfidic ores. In the first step, ore flotation allows the obtainment of a bulk copper-zinc concentrate and low-toxicity waste. In the second step, zinc is selectively extracted by chemical leaching with a biogenic ferric iron solution, while copper is accumulated in the leach residue. Importantly, the efficiency of this step depends on the chemical and mineralogical composition of polymetallic concentrates. Four samples of the copper-zinc sulfide concentrate with various contents of copper and zinc have been leached in multiple cycles at 80 °C, 10% of pulp density, and pH 1.3-1.5. The leaching of the concentrate that contained 14.7% of copper and 5.0% of zinc for three leaching cycles (total duration, 5.75 h) allowed the obtainment of a leach residue containing 15.3 and 0.14% of copper and zinc, respectively. At the same time, the leaching of another concentrate that contained 19.2% of copper and 2.64% of zinc after one leaching cycle (total duration, 0.67 h) led to copper and zinc contents of 19.1 and 0.72%, respectively, in the leach residue. Therefore, the treatment of only two concentrates allowed the obtainment of high-grade copper concentrates containing low amounts of zinc. Ferric iron, the oxidant of sulfide minerals, was fully regenerated in leachate within 30-35 h at 40 °C using an acidophilic microbial community dominated by Leptospirillum ferriphilum, Sulfobacillus spp., and Ferroplasma acidiphilum. The loss of copper and zinc in solid waste of the bioregeneration did not exceed 1.0% and 1.8%, respectively. The proposed flowsheet of bulk concentrate processing has several important advantages over conventional technologies, including short duration of leaching, formation of low-toxicity solid waste, and pyrometallurgical processing of only high-grade copper concentrates. This approach can be a promising solution for the efficient processing of polymetallic bulk concentrates.

Distinct Roles of Acidophiles in Complete Oxidation of High-Sulfur Ferric Leach Product of Zinc Sulfide Concentrate.

A two-step process, which involved ferric leaching with biologically generated solution and subsequent biooxidation with the microbial community, has been previously proposed for the processing of low-grade zinc sulfide concentrates. In this study, we carried out the process of complete biological oxidation of the product of ferric leaching of the zinc concentrate, which contained 9% of sphalerite, 5% of chalcopyrite, and 29.7% of elemental sulfur. After 21 days of biooxidation at 40°C, sphalerite and chalcopyrite oxidation reached 99 and 69%, respectively, while the level of elemental sulfur oxidation was 97%. The biooxidation residue could be considered a waste product that is inert under aerobic conditions. The results of this study showed that zinc sulfide concentrate processing using a two-step treatment is efficient and promising. The microbial community, which developed during biooxidation, was dominated by Acidithiobacillus caldus, Leptospirillum ferriphilum, Ferroplasma acidiphilum, Sulfobacillus thermotolerans, S. thermosulfidooxidans, and Cuniculiplasma sp. At the same time, F. acidiphilum and A. caldus played crucial roles in the oxidation of sulfide minerals and elemental sulfur, respectively. The addition of L. ferriphilum to A. caldus during biooxidation of the ferric leach product proved to inhibit elemental sulfur oxidation.

Two-step biohydrometallurgical technology of copper-zinc concentrate processing as an opportunity to reduce negative impacts on the environment.

Polymetallic concentrates obtained during ore beneficiation pose a significant problem for the mining and metallurgy industry due to an increase in load on subsequent comminution steps and a high loss of metals in slag during smelting. Storage of such slag can lead to pollution of groundwater due to weathering. Biohydrometallurgy is an option for the processing of sulfidic raw materials that has a low impact on the environment. Processing of sulfidic concentrates of copper-zinc ore via bioleaching techniques was studied in this paper. Three mixed microbial cultures of acidophilic microorganisms were enriched from industrial mining sites: two autotrophic mesophilic cultures containing Acidithiobacillus ferroxidans and Leptospirillum spp. (grown at 30 and 35 °C), and a mixotrophic moderate thermophilic culture containing Sulfobacillus thermotolerans, Leptospirillum ferriphilum, as well as the archaea Ferroplasma acidiphilum and Acidiplasma spp. (grown at 40 °C). The autotrophic microbial culture growing at 30 °C was used to generate an iron-containing biosolution for ferric leaching of a copper-zinc concentrate. Zinc and iron extracted into solution faster than copper during high-temperature (80 °C) ferric leaching of the concentrate due to galvanic interactions between minerals, redox conditions of the medium, and differences between mineral oxidation mechanisms. Weight loss of the leach residue was 34.0%, with relative copper content increased by 1.0%, zinc content decreased by 6.18%, and iron content decreased by 15.1%. Biooxidation of ferrous iron in the pregnant leach solution by three microbial cultures was also studied. The most effective culture was moderate thermophilic. The results of studies on the bioregeneration of leaching solutions are relevant to the development of a two-step biohydrometallurgical technology for processing of copper-zinc concentrate with a closed cycle of technological flows. The ferrous iron biooxidation rate by the moderate thermophilic culture reached 20 g L-1 day-1. The leach residue obtained can be considered a high-grade copper concentrate able to be processed via smelting. This bioleaching process would make it possible to reduce pollution of groundwater by some toxic metals stored in slags. An environmentally friendly technology flow sheet for copper-zinc sulfidic ore processing using two-step bioleaching treatment was proposed.