1. Introduction
With increasing global demand for clean and stable energy, nuclear power continues to play a vital role in energy transition strategies. Uranium, as the primary fuel for nuclear power generation, has become strategically important. Sandstone-hosted uranium deposits represent the most important uranium resource type in China and are predominantly exploited using in situ recovery (ISR) technology [
1].
In ISR, groundwater is first pumped to the surface via extraction wells. Leaching reagents are then added to the groundwater, which is injected back into the ore-bearing aquifer through injection wells, dissolving uranium minerals and mobilizing uranium from the solid phase into the groundwater. The uranium-bearing groundwater is subsequently extracted to the surface and uranium is subsequently recovered at the surface using ion-exchange resins [
1].
ISR uranium extraction is classified by the type of chemical reagent added: Acid leaching (sulfuric acid), alkaline leaching (sodium bicarbonate + ammonium bicarbonate), and CO
2 + O
2 leaching [
1]. Since ISR minimally alters the ore’s original texture and mineral composition, ISR performance is strongly controlled by the mineralogical composition, textural features, and uranium occurrence of the ores [
2,
3,
4,
5,
6,
7]. Uranium minerals are typically the primary hosts of uranium in deposits [
8], but different uranium minerals exhibit different dissolution kinetics under varying lixiviant systems, including acidic, alkaline, and CO
2 + O
2 systems [
9,
10,
11]. Even the same uranium mineral may display different leaching behaviors depending on impurity content and crystal chemistry [
12,
13]. Generally, uranium minerals leach faster and more completely under acid conditions compared to other reagents. Beyond uranium mineral types, their contact relationships with other minerals and degree of liberation also affect leaching [
14,
15]. For instance, highly liberated uranium minerals have a greater contact area with leaching agents, facilitating extraction. Uranium minerals encapsulated by insoluble silicates like feldspar-quartz are difficult to access and leach. Those encapsulated by soluble minerals like calcite require higher CO
2 concentrations to dissolve the calcite and increase uranium liberation. Additionally, other gangue minerals in the ore can significantly influence leaching process selection. Carbonate minerals significantly influence leaching chemistry. In acid systems, their dissolution increases acid consumption and may lead to CaSO
4 precipitation, causing pore clogging and permeability reduction [
7,
16,
17,
18]. In contrast, under CO
2 + O
2 conditions, carbonate dissolution provides bicarbonate ligands necessary for uranyl complexation [
13]. Sulfide minerals such as pyrite may consume oxygen and produce Fe(OH)
3 precipitates, potentially impairing permeability [
4,
13,
19,
20,
21]. Therefore, detailed mineralogical characterization is essential for optimizing ISR strategies.
This study focuses on the Zhenyuan sandstone-hosted uranium deposit in the southwestern Ordos Basin. By integrating mineralogical analysis with laboratory leaching experiments, we evaluate uranium occurrence, the dissolution behavior of uranium and gangue minerals, and identify the most suitable leaching process.
3. Materials and Methods
Thirty core samples from five drills were collected for mineralogical investigation and leaching experiments. Thin sections were prepared for SEM observation and in-suit leaching tests. SEM analysis was conducted using a ThermoFisher (Waltham, MA, USA) Nova Nano SEM450 at the Beijing Research Institute of Uranium Geology, with an accelerating voltage of 15 kV and working distance of 5–10 mm. XRD analysis was performed using a Bruker (Billerica, MA, USA) Panalytical X’Pert PRO X-Ray diffractometer at the Beijing Research Institute of Uranium Geology, with operating conditions of 40 kV and 40 mA, and a scanning range of 5–70°. EPMA analyses were performed on JEOL (Tokyo, Japan) JXA-IHP200F at the Beijing Research Institute of Uranium Geology, with an accelerating voltage of 15 kV, working current of 10−8 A, working distance of 5–10 mm.
Thin-section leaching test: Thin-section leaching was conducted under conditions of 0.2 MPa CO2 + 1 MPa O2. The process involved introducing 0.2 MPa CO2 for 4 h, followed by 1 MPa O2 for 7 days at room temperature. Before leaching, the morphology of pitchblende and gangue minerals was observed, and their locations were documented using SEM. After leaching, the pre-observed uranium and gangue minerals were relocated for morphological comparison.
Acid Stirring Leaching: Each experiment used 60 g of ore sample mixed with 300 mL of sulfuric acid solution prepared with groundwater in ore-bearing aquifer, stirred for 24 h at room temperature.
Alkaline Stirring Leaching: Each experiment used 60 g of ore sample mixed with 300 mL of NH4HCO3 solution prepared with ore-bearing aquifer water, stirred for 72 h at room temperature.
CO2 + O2 Pressurized Stirring Leaching: Each experiment used 60 g of ore sample with 300 mL of ore-bearing aquifer water. During the experiment, 0.2 MPa CO2 was introduced for 3 h every 48 h, while O2 was introduced for the remaining time until the end.
CO2 + O2 Pressurized Column Leaching Test: The column leaching test was conducted under the following conditions: 700 g of ore sample was packed into a stainless-steel column with an inner diameter of 25 mm, resulting in a packing height of approximately 1000 mm, a packed volume of 491 mL, and a packing density of 1.43 kg/L. After packing, a certain volume of ore-bearing aquifer water was first passed through the column to pre-wet the ore bed. The effluent from this pre-wetting stage was collected and analyzed. A cumulative volume of 1200 mL of ore-bearing aquifer water effluent was obtained, with a uranium concentration of 14 mg/L. This corresponded to the leaching of 0.0168 g of metallic uranium, yielding an initial recovery of 7.74%. Subsequently, the formal CO2 + O2 pressurized leaching commenced by injecting a leaching agent prepared by saturating ore-bearing aquifer water with carbon dioxide and oxygen. The gas pressures were set at 0.2 MPa for CO2 and 1.0 MPa for O2. The effluent flow rate was controlled to simulate the hydrodynamic conditions of an underground in situ leaching operation. The effluent volume and uranium concentration were recorded daily. The leaching process continued until the uranium concentration in the effluent consistently fell below 3 mg/L, which lasted for a total of 68 days from the start of lixiviant injection. The final liquid (mL)-to-solid (mg) (L/S) ratio reached 5.18, and the cumulative leaching recovery was 68.45%.
5. Discussion
The uranium occurrence state, the types and abundance of gangue minerals, and the pore structure of the ore are critical factors influencing the ISR efficiency of sandstone-hosted uranium deposits [
2]. The combined observations and analyses by SEM-EDS and EPMA confirm that uranium in the Zhenyuan Deposit primarily exists as pitchblende (
Figure 4). Additionally, a small fraction occurs as solid solution within Ti-oxides and dolomite lattices, while a trace amount is adsorbed onto chlorite (
Figure 5,
Table 3 and
Tables S2–S4).
Pitchblende (uraninite) is the most economically significant uranium mineral globally. Compared to other economically important uranium minerals like coffinite and brannerite, pitchblende is more amenable to leaching [
8]. The dissolution of pitchblende under CO
2 + O
2 leaching condition involves: (1) The oxidation of tetravalent uranium (U
4+) to hexavalent uranium (U
6+) on the surface; (2) binding of HCO
32− at the U(VI) sites of the oxidized layer; and (3) detachment of the U(VI)-carbonato surface complex [
21,
22]. In the CO
2 + O
2 leaching system, oxygen (O
2) acts as the primary oxidant. Meanwhile, dissolved CO
2 forms carbonic acid (H
2CO
3), which dissociates to provide bicarbonate ions (HCO
3−). Additionally, the reaction between H
2CO
3 and carbonate minerals such as calcite and dolomite, produce HCO
3−, which then serves as a complexing ligand for uranyl ions (UO
22+). The oxidation of U
4+ under weakly acidic to near-neutral conditions is a pseudo-first-order reaction. The oxidation mechanism involves the adsorption of oxygen onto the pitchblende surface, the formation of pentavalent uranium (U
5+), and its subsequent reaction with oxygen. Once sufficient U
6+ accumulates, its reaction with remaining U
4+ to form U
5+ may become the rate-limiting step [
8,
12]. Ultimately, U
6+ reacts with bicarbonate to form soluble uranyl carbonate complexes, predominantly uranyl tricarbonate [UO
2(CO
3)
3]
4− [
6]. The thin-section leaching results demonstrate that pitchblende particles were completely dissolved under the experimental conditions of 0.2 MPa CO
2 for 4 h followed by 1 MPa O
2 for 7 days (
Figure 6). This confirms the high leachability of pitchblende in this deposit. Moreover, both stirred tank and column leaching experiments yielded high uranium recovery rates, substantiating the effectiveness of the CO
2 + O
2 method for Zhenyuan ores. Importantly, SEM observations reveal that pitchblende in the Zhenyuan Deposit predominantly occurs as nano-spherical particles and as thin films (<2 μm thick) coating the surfaces of Ti-oxides. Such morphologies substantially increase the specific surface area of the uranium-bearing phases, maximizing the contact area with the lixiviant and thus favoring rapid dissolution (
Figure 4). Furthermore, pitchblende was not found to be encapsulated by either refractory silicate minerals (e.g., quartz, feldspar) or readily soluble carbonates (e.g., calcite), indicating a high degree of mineral liberation. A high liberation degree is also conducive to efficient contact and reaction between uranium minerals and the leaching reagents. In addition to pitchblende, uranium also exists within Ti-oxide and dolomite lattices. The SEM observations from thin-section leaching experiments confirmed that both Ti-oxide and dolomite underwent partial dissolution to varying degrees. Therefore, this portion of uranium can also be extracted during the leaching process. In summary, the favorable uranium occurrence characteristics in Zhenyuan ores—primarily as accessible pitchblende with high specific surface area and liberation degree—are all advantageous for uranium extraction.
The types and abundances of gangue minerals also significantly influence uranium leaching. In Zhenyuan ores, quartz and feldspar account for an average of approximately 93.6 wt%, with quartz content typically exceeding 85 wt%. These framework silicate minerals are chemically stable under leaching conditions and react minimally with lixiviants, which is beneficial for the process. However, the ores also contain more than 5 wt% of dolomite and calcite. These carbonates are primarily distributed along the edges of quartz-feldspar framework grains, creating more complex and variable pore structures. Such complexity can increase turbulence and hydraulic resistance during the injection-production cycle, leading to higher injection pressures. Our analysis further indicates that in samples with comparable porosity, the presence of dolomite significantly reduces both gas and liquid permeability, suggesting a damaging effect on rock permeability. Under sulfuric acid leaching conditions, dolomite would react vigorously, resulting in unacceptably high acid consumption and increased economic costs for deposit exploitation. Moreover, this reaction promotes gypsum (CaSO
4·2H
2O) precipitation, potentially clogging the ore-bearing aquifer. Given the high carbonate mineral content in this deposit and the high acid consumption confirmed by stirred leaching tests, the sulfuric acid leaching method is not suitable for the Zhenyuan Deposit. In contrast, under CO
2 + O
2 leaching conditions, calcite dissolves completely, and dolomite undergoes significant partial dissolution (
Figure 7). The dissolution of carbonate minerals enhances the bicarbonate concentration in the groundwater, providing essential ligands for uranium complexation and thus facilitating uranium extraction. The column leaching test results showed that when the L/S ratio reached approximately 3.2, the bicarbonate concentration in the leachate began to decrease, accompanied by a synchronous decline in uranium concentration (
Table 8). This likely indicates that the inherent carbonate minerals in the ore were insufficient to supply the HCO
3− required for sustained leaching. Notably, increasing the CO
2 pressure subsequently led to a temporary increase in uranium concentration, highlighting the role of carbonate dissolution. In a practical ISR operation, where ore-bearing aquifer water is continuously recirculated between injection and production wells, bicarbonate ions would accumulate over time, further promoting leaching. Furthermore, porosity and permeability tests indicate that the Zhenyuan Deposit possesses relatively high porosity and permeability (
Table 2). Both XRD and SEM results show that the clay mineral content in the ore is very low (
Table 1 and
Figure 1). The intergranular pore spaces are primarily filled with dolomite and calcite, or these minerals line the framework grain boundaries (
Figure 1). Therefore, the dissolution of these carbonates during CO
2 + O
2 leaching can also improve the overall permeability of the deposit [
23]. Additionally, the well-consolidated nature of the ore, coupled with low contents of clay and fine-grained quartz/feldspar particles within the pores, will help minimize particles migration during leaching. This reduces the risk of aquifer clogging and the associated decline in injection and production rates often encountered during ISR operations due to particle clogging. While the thin-section leaching confirmed that the dissolution of dolomite was limited at 0.2 MPa CO
2, it also demonstrated that its dissolution not only contributes to bicarbonate ions but also enhances permeability. Thus, we recommend employing higher CO
2 injection pressure during actual mining operations.
The Zhenyuan ores also contain minor pyrite. Pyrite is considered a significant oxygen-consuming mineral during CO
2 + O
2 leaching. Furthermore, its oxidation produces sulfate ions, which can combine with calcium ions to form gypsum precipitates, while ferric iron (Fe
3+) forms iron hydroxide colloids, both potentially clogging the ore-bearing aquifer. However, the thin-section leaching results suggest that the degree of pyrite dissolution under 0.2 MPa CO
2 + 1 MPa O
2 was far less pronounced compared to pitchblende and dolomite (
Figure 7). Therefore, in the initial leaching stages, pyrite may not be the primary oxygen consumer. Due to its relatively slow dissolution rate, the negative impact of its oxidation products (e.g., gypsum, Fe(OH)
3) on permeability may also be limited initially. Nonetheless, as leaching progresses with continued pyrite dissolution, the permeability damage from these precipitates could increase over time.
Overall, the key characteristics of the Zhenyuan Deposit—high content of stable framework silicates (quartz, feldspar), well-consolidated rock fabric, significant but manageable carbonate mineral content, low sulfide (e.g., pyrite) abundance, and uranium primarily occurring in highly leachable pitchblende forms—collectively indicate excellent leachability. These features strongly suggest that the deposit is well-suited for exploitation using the CO2 + O2 ISR process. Additionally, we recommend that appropriately increasing the CO2 injection pressure during operation to enhance dolomite dissolution would further optimize leaching efficiency.