Bioleaching Capacity of An Extremely Thermophilic Culture

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Minerals Engineering 15 (2002) 689–694

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Bioleaching capacity of an extremely thermophilic culture


for chalcopyritic materials
A. Rubio a, F.J. Garcıa Frutos b,*

a
Instituto Geol
ogico y Minero de Espa~
na (IGME), La Calera n° 1, 28760 Tres Cantos, Madrid, Spain
b
Centro de Investigaciones Energ
eticas, Medioambientales y Tecnol
ogicas (CIEMAT), Av. Complutense 22, Edificio 20, 28040 Madrid, Spain
Received 9 March 2001; accepted 2 May 2002

Abstract
A thermophilic culture specific to bioleaching chalcopyritic materials has been obtained from a typical chalcopyritic copper
concentrate of the Spanish Pyritic Belt. This paper shows the effect of pulp density (w/v) on bioleaching culture capacity with respect
to this copper concentrate. The results of the batch tests show that it is possible, operating at 10% of pulp density to attain copper
extraction of 94% in 10 days and, at higher pulp densities (20%), to attain good copper extraction (80%) in only 14 days. In the same
way, the culture has been amply tested with different chalcopyritic ores and copper concentrates. The results obtained with four of
these materials, two refractory gold ores and two copper concentrates are also presented. These results show a varying and versatile
bioleaching capacity of this bacterial culture. A model of bacterial attack of this culture to leach chalcopyrite is postulated.
Ó 2002 Elsevier Science Ltd. All rights reserved.

Keywords: Mineral processing; Sulphide ores; Hydrometallurgy; Bioleaching and bacteria

1. Introduction metal concentrates, this technology remains as a prom-


ising alternative against conventional pyrometallurgical
The resources of high ores in the world are becoming extraction processes. This is the case of the treatment
more and more scarce making the processing of more of chalcopyritic concentrates, which represent a more
complex ores necessary. Conventional mineral process- complicated situation, due to the natural refractivity of
ing on complex sulphide ores carried out by differential chalcopyrite.
flotation often produces high grade concentrates but One of the mainly problems of the bioleaching pro-
with contaminants that penalise and make its marketing cesses applied to copper concentrates and refractory ores
and pyrometallurgical processing difficult. Therefore, a are the low kinetics of the reactions, with high residence
lot of effort has been made in the development of hy- time that does not permit it to be an economic process.
drometallurgical process suitable for the treatment of For this reason, current researches into this field are
these ores, but most of the proposed methods are focused on how to increase this bioleaching rate. Apart
complex and expensive, Alvarez (1996). from improving engineering design of bioreactors, the
Among these hydrometallurgical processes, biohy- possibilities to increase bioleaching rates depend on the
drometallurgical techniques appear to be an alternative use of catalyst and isolation and adaptation of new mi-
for the treatment of these concentrates. These methods, croorganisms with high capacity to leach these ores.
that were first applied industrially to copper and ura- Several studies with mesophilic microorganisms as
nium productions using bioassisted heap, dump and Thiobacillus ferrooxidans and Leptospirillum ferrooxi-
in situ technologies, are successfully used today in ex- dans had showed very slow copper leaching rates, Mehta
traction of gold from refractory sulphide-bearing ores (1982) and Sand et al. (1992). However, when thermo-
and concentrates, Jordan et al. (1996). However, for other philic microorganisms were used leaching rates were
considerably increased due to high temperatures, higher
*
Corresponding author. Tel.: +34-91-3466232; Fax: +34-91-
metal tolerance capacity and metabolic characteristics of
3466269. this type of microorganisms, Brierley (1993) and Clark
E-mail address: garcia.frutos@ciemat.es (F.J. Garcıa Frutos). and Norris (1996).
0892-6875/02/$ - see front matter Ó 2002 Elsevier Science Ltd. All rights reserved.
PII: S 0 8 9 2 - 6 8 7 5 ( 0 2 ) 0 0 1 2 4 - 3
690 A. Rubio, F.J. Garcıa Frutos / Minerals Engineering 15 (2002) 689–694

Many researches have investigated the possibility of This paper describes the bioleaching capacity of the
using thermophilic microorganisms to improve metal culture to operate at high pulp density and its versatility
leaching rates instead to mesophilic microorganisms. for leaching chalcopyritic materials, from ores to con-
Future process developments must and will include centrates, postulating an ‘‘in situ’’ indirect bacterial at-
thermophilic bacteria, which will play an increasingly tack.
important role in biooxidations of minerals. Thermo-
philic Archaea, Sulfolobus species, Acidianus brierleyi
and Metallosphaera sedula which grow from 60 to 75 °C, 2. Methods
are particularly adept in bioleaching of copper from the
highly refractory chalcopyrite, Brierley and Brierley 2.1. Microbial inoculum
(1999) and Dew et al. (1999). Moreover, the use of these
microorganisms that naturally thrive on ore samples and A mixed thermophilic culture (MTC) of native mi-
its aqueous environments, could be a good option as croorganisms, isolated on a typical chalcopyritic con-
they probably have specificity for leaching chalcopyrite centrate described below (Concentrate 0), was used as
and a much higher capacity for adaptation. In this sense, inoculum in the initial bioleaching experiments.
there is a work carried out by Lopez-Archilla et al. The methodology of the isolation was the following:
(2001), on the microbial ecology of Rio Tinto waters, The concentrate was strong stirring (360 rpm) at pH
where they report to have isolated a thermophilic ar- higher than 4 and 65 °C of temperature during 2 h for
chaeabacteria, Sulfolobus rivotincti, with specificity to remove the microorganisms attached on the chalcopy-
bioleach chalcopyrite and therefore with possibilities to rite surface. Once the microorganisms were unattached
be used in chalcopyritic concentrates treatment, Bal- and free in solution, the solid was removed of the liquid
lester (1996) and G omez et al. (1999). by filtration. The bacteria-laden liquid obtained was
The use of these microorganisms for bioleaching filtered through a 0.22 lm Millipore membrane filter to
chalcopyrite implies the knowledge of the mechanisms collect the microorganisms, which were suspended in
involved in the process. 1:10 9 K medium at pH 1.30.
Initially, chalcopyrite can be oxidised by dissolved Preliminary comparative bioleaching tests were per-
oxygen according to Eq. (1), Hiroyosi et al. (1997), fa- formed using a bacterial inoculum of Sulfolobus sp.
voured for acidic solution, and as it is known, two kindly supplied by Dr. F. Carranza, Universidad de
modes of bacterial attack can be distinguished: Sevilla, Spain.
In indirect attack (Eq. (2)), the role of bacteria is to Both thermophilic cultures were maintained on cop-
regenerate the oxidant ferric ion in the bulk phase, from per concentrate (Concentrate 0) at 1% w/v pulp density
the ferrous iron resulting from the chemical oxidation medium with 1:10 salts of 9 K medium at 65 °C of
of the metal sulphide in the ore by ferric iron (Eq. (3)). temperature and initial pH of 1.30.
In the direct attack, the bacteria leach the metal sul- The cultures were successfully adapted to higher pulp
phide by attaching to the mineral surface and oxidising density of copper concentrate until obtaining high cop-
it enzimatically by conveying electrons from the reduced per extractions in short residence times. In these tests,
moiety of the mineral, Erlich (1999). the inoculum was obtained as the culture isolation was
made.
CuFeS2 þ O2 þ 4Hþ ¼ Cu2þ þ Fe2þ þ 2S0 þ 2H2 O
The final pulp of the bioleching test was filtered,
ð1Þ obtaining the leach liquor and the solid residue. The
CuFeS2 þ 4Fe 3þ
¼ Cu 2þ
þ 5Fe 2þ
þ 2S 0
ð2Þ solid was intensively stirring during 2 h with water at pH
2þ þ 3þ 4. The pulp obtained was filtered again and the final
4Fe þ 4H þ O2 ¼ 4Fe þ 2H2 O ð3Þ liquid obtained, which contains most the bacteria, which
Sand (1997) have suggested that because Fe3þ oxi- were attached to the solid residue, was filtered through a
dises metal sulphide with both the direct and indirect 0.22 lm Millipore filter where bacteria were retained.
mechanisms, there is no difference between the two Finally, the bacteria were re-suspended in 50 ml of the
mechanisms. Their model emphasises a similarity in the leach liquor obtained in the first filtration in order to get
chemistry of attack of the sulphide moiety by iron, and the inoculum volume (5% v/v) for the next bioleaching
makes no distinction between ferric iron in the bulk test.
phase and ferric iron bound in the cell envelope.
The authors have obtained a mixed natural thermo- 2.2. Ore samples
philic culture from a typical chalcopyiritic copper con-
centrate of the Spanish Pyritic Belt, Rubio (1998). This A chalcopyritic copper concentrate obtained from
culture has selectivity with respect to leaching chal- conventional differential flotation was used to develop
copyrite, when this is present together with other sulp- the mixed thermophilic culture. This concentrate (Con-
hides in ores and concentrates. centrate 0) came from the Spanish Pyritic Belt and its
A. Rubio, F.J. Garcıa Frutos / Minerals Engineering 15 (2002) 689–694 691

Table 1 ished, solids were removed by filtration, and chemically


Chemical composition of copper concentrate characterised as well as the leachate.
Sample Chemical analysis (wt%) Sterile bioleaching tests were carried out with ore
Cu Zn Pb Fe S sterilised by autoclaving at 121 °C, 30 min and 1atm of
Concentrate 0 23.37 2.58 2.52 32.63 38.00 pressure, and adding a solution of 10% ethanol to the
leaching media.

composition is given in Table 1. The mineralogical 2.4. Analysis


composition of this sample shows chalcopyrite and py-
rite as main mineralogical species and galena and Soluble species of copper, zinc, lead, total iron and
sphalerite as secondary mineralogical phases. The par- minor elements were analysed by ICP, Del Barrio
ticle size distribution presents a passing d80 of 20 lm. (1992), using a spectrophotometer ICAP-61 Thermo
Concentrate 1, also used in bioleaching tests is es- Jarrel Ash. The ferrous iron was analysed by a volu-
sentially the same as Concentrate 0, corresponding to metric method by titration with potassium dichromate,
another lot of copper concentrate obtained in the same Kolthoff (1979). Copper, zinc, lead and iron content in
flotation point at the industrial plant. This sample pre- the ore samples and leaching solid residues were analy-
sents less copper content and higher zinc content than sed by XRF, Martın Rubı (1998), using a spectropho-
Concentrate 0. tometer Philips PW-1404, and minor elements by ICP.
The other chalcopyritic samples, refractory gold ores Total sulphur was gravimetrically determined and ele-
(Ores 1 and 2) and copper concentrates (Concentrate 1 mental sulphur was analysed by toluene extraction in
and 2), also came from the Spanish Pyritic Belt, were a Soxhlet apparatus.
selected in this work to study the selectivity of the MTC The pH was measured with a 704 pH-meter Metr-
to chalcopyrite. The chemical composition of these ohm. The redox potential (Eh) was measured with a
chalcopyritic samples is given in Table 2. The copper platinum electrode with an Ag/AgCl reference electrode.
present in these samples is as chalcopyrite. Mineralogical composition was determined by XRD
using a difractometer PW-1700 Philips.
2.3. Bioleaching experiments

Bioleaching experiments were carried out in 1 l glass 3. Results and discussion


cylindrical reactors provided with a cap with four holes
to allow mechanical stirring (at 130 rpm), aeration (10– 3.1. Influence of pulp density
15 l/h) and sampling. These reactors were placed in a
thermostatic bath to keep the temperature constant at A study of bioleaching capacity on copper concen-
65 °C. trates by MTC culture was done at different pulp den-
During the experiments the pH was kept at 1.30 by sities such as 1%, 5%, 10%, 15% and 20% (w/v).
the addition of 10N H2 SO4 when were necessary. This Preliminary tests carried out at 1% pulp density (w/v)
10 N H2 SO4 addition was made to avoid the precipita- show a higher capacity of MTC culture to bioleach the
tion of iron in form of jarosites, which damage the bio- copper present in the copper concentrate (Concentrate
leaching process. 0) compared to the tests carried out with Sulfolobus sp.
Redox potential and pH were measured daily, while culture (Sb) on the same copper concentrate. Both cul-
the levels of copper, zinc, and iron in solution were tures had been maintained and adapted to this copper
analysed daily or every 2 days, depending on the test. concentrate by successive sub-culturing for the realisa-
Water was added to the reactors in order to compensate tion of these bioleching tests.
for evaporation losses. Once bioleaching tests were fin- Fig. 1 shows copper extractions obtained on copper
concentrate with MTC and Sb cultures in representative
adaptation tests at 1% of pulp density (w/v). In the
Table 2 sterile test, only 11 % copper extraction was obtained in
Chemical composition of chalcopyritic samples more than 500 h. In bioleaching tests with Sulfolobus sp.
Sample Chemical analysis (wt%) culture (Sb), initially a cooper extraction up 98% was
Cu Zn Pb Fe S reached in 500 h, but after successive adaptation tests,
Ore 1 0.69 1.64 0.71 39.55 33.35 the kinetic of reaction was increasing, obtaining maxi-
Ore 2 1.47 1.1 0.53 42.15 45.6 mum copper extractions (>98%) in 350 h. However,
Concentrate 1 20.76 4.65 2.87 30.11 37.29 with MTC culture the same copper extraction (more
Concentrate 2 6.70 <0.10 <0.10 24.20 n.a. than 98%) was obtained in only 165 h with only two
n.a: no appear. successive adaptive tests.
692 A. Rubio, F.J. Garcıa Frutos / Minerals Engineering 15 (2002) 689–694

Fig. 3. Comparative copper extraction at the different pulp densities


studied (1, 5, 10, 15 and 20% (w/v) at pH 1.30 and 65 °C). Sample:
Fig. 1. Copper extraction in bioleaching adaptive tests at 1% (w/v)
Concentrate 0.
pulp density. (Sterile test, Sulfolobus sp. and MTC tests at pH 1.30 and
65 °C). Sample: Concentrate 0. (The sub-indexes 1; 2; 3; . . . ; n corre-
spond to consecutive tests.)
density (20%) obtaining good copper extraction (80%)
and with lower pulp density (10%) obtaining better
Bioleaching tests carried out at 5% pulp density (w/v) copper extraction (94%) in 14 and 10 days respectively.
are shown in Fig. 2. Similar ability to preferentially In all tests done at different pulp densities, iron in
leach copper by MTC thermophilic culture was ob- solution at first stages was mainly as ferrous iron and
tained. The extractions achieved with the MTC were only the presence of ferric iron was more notable when
much more significant than Sb culture. It can be ob- almost 80% of copper is leached.
served that in the first test on Concentrate 0 with the Fig. 4 shows total iron and ferrous iron during a bio-
culture isolated MTC, a copper extraction of about 90% leaching test on Concentrate 0 at 10% of pulp density
was obtained in only 21 days. In second test with this with MTC culture. As it can be observed, mainly form
culture, in 17 days the copper extraction reached 97%, of iron in solution was as ferrous iron. This ferrous iron
considerably higher than the extraction attained (80%) in solution decreases at the final stages (from the eighth-
after 56 days of bioleaching when Sulfolobus sp. culture day on) which corresponds to an increase in the solution
was used. redox potential over 450 mV and a copper dissolution of
From these results, a study in order to define the 80%.
optimum conditions of this bioleaching process was Redox potential evolution is showed in Fig. 5. As can
carried out increasing pulp density (1%, 5%, 10%, 15% be seen, Eh in first stages of bioleaching is about 400 mV
and 20% (w/v)). This study is described elsewhere, to reach 425 mV in an intermediate step, confirming the
Rubio (1998). The best conditions obtained from 1% most presence of ferrous iron in solution. The more
to 20% pulp densities vary only in oxygen uptakes. notable redox potential increase was produced from day
In Fig. 3 appears the evolution of copper extractions 7, when ferrous iron starts to decrease in solution
to all tests done at pulp densities studied in its optimum reaching a final Eh of 475 mV.
conditions. As it can be observed the results of batch Fig. 6 shows zinc extraction in the same bioleaching
tests show that it is possible to work both with high pulp test. A fast initial leaching of zinc can be appreciated. At

Fig. 2. Copper extraction in bioleaching adaptive tests at 5% (w/v)


pulp density. (Sulfolobus sp. (Sb) and MTC tests at pH 1.30 and 65
°C). Sample: Concentrate 0. (The sub-indexes 1; 2; 3; . . . ; n correspond Fig. 4. Concentration of iron in leach solution to a representative test
to consecutive tests.) at 10% (w/v) pulp density, at pH 1.30 and 65 °C. Sample: Concentrate 0.
A. Rubio, F.J. Garcıa Frutos / Minerals Engineering 15 (2002) 689–694 693

Fig. 7. Copper extraction in bioleaching tests with copper Concentrate


Fig. 5. Redox potential (Eh) evolution to a representative test at 10% 1 and 2 (10% (w/v) pulp density, pH 1.3 and 65 °C).
(w/v) pulp density, at pH 1.30 and 65 °C. Sample: Concentrate 0.

done at 10% pulp density. The copper present in these


ores was quickly leached in 3 and 4 days, and the zinc
was only extracted when copper is almost leached and
the redox potential was over 475 mV.
Fig. 7 shows the copper extraction obtained in bio-
leaching tests carried out at 10% pulp density with the
other copper concentrates used (Concentrate 1 and 2).
Concentrate 2 with less initial copper content than
Concentrate 1, was more easily bioleached by MTC
culture, obtaining more than 90% of copper extraction
in 6 days. With Concentrate 1 (similar to Concentrate 0)
and without a period of adaptation, more than 70% of
copper extraction was obtained in 12 days. In the sterile
Fig. 6. Concentration of zinc in leach solution to a representative tests, copper extraction obtained was 14% for Concen-
test at 10% (w/v) pulp density, at pH 1.30 and 65 °C. Sample: Con- trate 1 and 21% for Concentrate 2.
centrate 0. From these tests it can be observed that the leaching
behaviour of this culture with respect to chalcopyrite
intermediate stage of leaching, as there are not sufficient present in these samples, was similar to the initial copper
ferric iron in solution, the zinc dissolution is low, and concentrate, leaching in a selective way this mineralog-
only an increase in zinc extraction was observed when ical species.
copper was bioleached (after 8 days of test) coinciding
with the increase of ferric iron in solution. 3.3. Mechanism of bioleaching
The zinc present was almost completely leached only
when the duration of tests was prolonged longer after all Three significant facts were observed in all bioleach-
copper had been leached. ing tests carried out with the MTC culture:
X-ray diffraction of solid residues showed elemental
sulphur and pyrite as main species present, and anglesite 1. Iron in solution was mainly found as ferrous iron.
and sphalerite as minor species. 2. Only when copper extraction was significant the pres-
ence of ferric iron in solution was more notable.
3.2. Bioleaching of chalcopyritic samples 3. Zinc extractions were only about 60%, being almost
constant along the leaching time.
In Table 3, appear in short, the results obtained with
the two refractory gold ores selected. The tests were In addition to the high temperature of leaching, these
characteristics may have a significant incidence on the
high bioleaching rate obtained with MTC culture. From
Table 3
Results obtained in bioleaching tests with the refractory gold ores
these facts the following ‘‘in situ’’ indirect leaching
model may be considered:
Sample Pulp density Time Yield (%)
(% w/v) (days)
In acidic solution, chalcopyrite is oxidised by dis-
Cu Zn Fe
solved oxygen according to the reaction in Eq. (1), Hi-
Ore 1 10 3 90.20 70.59 11.52 royosi et al. (1997). In addition to this reaction, the Eq.
Ore 2 10 4 89.16 59.02 23.99
(3) occurs in the presence of ferrous ions. If ferric ions
694 A. Rubio, F.J. Garcıa Frutos / Minerals Engineering 15 (2002) 689–694

were produced by the reaction in Eq. (3), chalcopyrite carried out for your assistance in the analyses and ex-
oxidation by ferric ions would be taking place in addi- periments.
tion to reaction in Eq. (1) through the reaction in
Eq. (2).
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We would like to thank A. Ilarri, researchers and Symposium IBS97 BIOMINE97. Australian Mineral Foundation,
technicians of IGME Laboratory where this study was Glenside, SA.

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