Maxim I. Muravyov

Biohydrometallurgical technology of copper recovery from a complex copper concentrate

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 hours, which allowed extraction of 40.6% of copper. At subsequent chemical leaching at 80°C during 7 hours with a solution of ferric sulfate obtained after biooxidation by an association of micro-organisms, the rate of copper recovery was 52.7 g/kg h. The total copper recovery was 94.5% (over 29 hours). Regeneration of the Fe3+ ions was carried out by an association of moderately thermophilic microorganisms, including bacteria of genus Sulfobacillus and archaea Ferroplasma acidiphilum, at 1.0 g/L h at 40°C in the presence of 3% solids obtained by chemical leaching of copper concentrate. A flowsheet scheme of a complex copper concentrate process with the use of bacterial-chemical leaching is proposed.

Bioprocessing of Mining and Metallurgical Wastes Containing Non-Ferrous and Precious Metals

Mining and metallurgical treatments of sulphide ores are characterised by present significant losses of non-ferrous and precious metals as different types of waste. These elements are accumulated in heaps due to the lack of efficient technology for the recovery of the metals from metallurgical waste. The treatment of two types of industrial metallurgical waste (copper converter slag and old flotation pyrite tailings) containing non-ferrous and precious metals were examined in the laboratory. Leaching of the slag containing 2.74% Cu (as digenite, bornite, and free metal) and 2.49% Zn (as a ferrite ZnFe2O4 and silicate) by an Fe3+-containing solution was studied. The effect of various experimental parameters on the leaching dynamics of copper, zinc, and iron under batch conditions was investigated. The following experimental parameters were recommended: a pH of 1.5, a pulp density of 10% (w/v), a temperature of 70 °C, and an initial Fe3+ concentration of 15 g/L. Leaching under these conditions resulted in the solubilisation of 89.4% copper and 35.3% zinc within 2.5 hours. Percolation leaching of the pyrite tailings containing 0.29% Cu (as chalcopyrite), 0.26% Zn (as sphalerite), 0.00007% gold, and 0.00108% silver was also studied. Acidic percolation leaching and the resulting biooxidation lasting 134 days resulted in the solubilisation of 73.4% zinc and 50.8% copper. The recovery rates of gold and silver from the bioleaching residues by cyanidation were 57.2% and 50.7%, respectively. The data obtained in the present work may be used to estimate the operating parameters for the industrial-scale processing of non-ferrous and precious metals from mining and metallurgical waste.

Leaching of rare earth elements from coal ashes using acidophilic chemolithotrophic microbial communities

A method for leaching rare earth elements from coal ash in the presence of elemental sulfur-oxidizing communities of acidophilic chemolithotrophic microorganisms was proposed. The optimal parameters determined for rare element leaching in reactors were as follows: temperature, 45°C; initial pH, 2.0; pulp density, 10%; and the coal ash to elemental sulfur ratio, 10 : 1. After ten days of leaching, 52.0, 52.6, and 59.5% of scandium, yttrium, and lanthanum, respectively, were recovered.

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.

A Two-Step Process for the Treatment of Refractory Sulphidic Concentrate

Methods for improving the treatment efficiency of a refractory gold-bearing sulphidic concentrate are proposed. These methods consist of the oxidation of the concentrate through a two-step process: a high-temperature ferric leaching step and a subsequent biooxidation step, which further involves the use of organic nutrients. The concentrate contained 34.7% pyrite and 7.9% arsenopyrite. The biooxidation of the concentrate (in a one-step process) was conducted at 45°C in bioreactors under continuous conditions. The pyrite and arsenopyrite oxidation levels after 240 hours were 60.2 and 92.0%, and the gold recovery level by cyanidation was 65.7%. The two-step process involved the leaching of the concentrate by a Fe3+-containing solution and the subsequent biooxidation of the leach residue. The pyrite andarsenopyrite oxidation levels after 240 hours of biooxidation were 65.7 and 94.1%, and the gold recovery level was 71.7%. The effect of an organic nutrient (yeast extract) on biooxidation during the two-step process was studied. The pyrite and arsenopyrite oxidation levels after 240 hours of biooxidation under mixotrophic conditions were 73.5 and 95.1%, and the gold recovery level was 77.9%. The effect of the organic nutrient on the microbial population was determined. Sulfobacillus thermosulfidooxidans and Acidithiobacillus caldus were the predominant microorganisms studied under both autotrophic and mixotrophic conditions. Archaeon Acidiplasma sp. MBA-1 was a minor component of the microbial community under autotrophic conditions but was one of the predominant microorganisms studied under mixotrophic conditions. The strain MBA-1 could oxidise both ferrous iron and elemental sulphur in the presence of yeast extract. These results suggest that the organic nutrient changed the composition and increased the activity of the microbial population. Thus, a two-step process with organic nutrients added during biooxidation may be considered an effective strategy for treating refractory pyrite-arsenopyrite concentrates.

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.

The effects of bioleaching conditions on the nonferrous metals content in copper-zinc concentrate

The effects of pH and ferrous iron concentration in cultural medium on the bioleaching of copper-zinc concentrate by mesophilic and moderately thermophilic acidophilic microorganisms were studied. It was revealed that the optimum pH for bioleaching in presence of 5 g/L of ferrous iron was 1.4–1.5. It was shown that bioleaching under optimal conditions led to an increase in the copper content in solid phase from 10.1 to 14% and a decrease in the zinc content from 7.4 to 1.4%. The results of the present work demonstrate that acidophilic microorganisms can be used for treatment of complex sulfide concentrates containing copper and zinc.

Investigation of steps of ferric leaching and biooxidation at the recovery of gold from sulfide concentrate

We examined the ferric leaching and biooxidation steps in a two-step biooxidation process of a gold-bearing sulfide concentrate containing pyrrhotite, arsenopyrite and pyrite. Ferric leaching of the concentrate (pulp density at 200 g/L) for 2 hours at 70°C at pH 1.4 by ferric sulfate solution (initial concentration at 35.6 g/L), which was obtained by microbial oxidation of ferrous sulfate allowed to oxidize 20.4% of arsenopyrite and 52.1% of sulfur. The most effective biooxidation of ferric leached concentrate was observed at 45°C in the presence of yeast extract. Oxidation of the sulfide concentrate in a two-step process proceeded more efficiently than in one-step. In a two-step mode, gold extraction from the residue was 10% higher and the content of elemental sulfur was two times lower than in a one-step process.

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.

Bioregeneration of the pregnant leach solutions obtained during the leaching of nonferrous metals from slag waste by acidophilic microorganisms

The bioregeneration of the solutions obtained after the leaching of copper and zinc from slag waste by sulfuric acid solutions containing ferric iron was examined. For bioregeneration, associations of mesophilic and moderately thermqophilic acidophilic chemolithotrophic microorganisms were made. It has been shown that the complete oxidation of iron ions in solutions is possible at a dilution of the pregnant leach solution with a nutrient medium. It has been found that the maximal rate of oxidation of iron ions is observed at the use of a mesophilic association of microorganisms at a threefold dilution of the pregnant leach solution with a nutrient medium. The application of bioregeneration during the production of nonferrous metals from both copper converter slag and its waste would make it possible to approach the technology of their processing using the closed cycle of workflows.