Search Results (18)

The accelerating transition to low carbon energy systems has intensified the demand for nickel and cobalt from low-grade (<1.5 wt.%) refractory lateritic ores. These low-grade laterites are however not amenable to conventional beneficiation due to their complex mineralogy, eclectic physicochemical properties, and fine Ni–Co dissemination. This review examines recent advances made in the extraction of nickel and cobalt from complex low-grade lateritic ores, emphasizing the interplay between ore mineralogy, chemistry, beneficiation, pretreatment, and processing route selection. Developments in selective ore comminution–classification have led to the generation of Ni-rich fine fractions (undersize) and Co-rich coarse fractions (oversize), enabling differentiated extraction strategies that improve resource utilization, frugal energy use, and process efficiency. Mechanical activation via stirred media milling, thermal calcination-induced structural disorder, and dehydroxylate goethite products, are shown to significantly enhance Ni–Co leaching kinetics under both atmospheric and heap leaching conditions. A critical comparison of pyrometallurgical (rotary-kiln electric furnace) and hydrometallurgical (HPAL, EPAL, heap, atmospheric, bioleaching) routes demonstrates that ore-specific optimization is essential to balance recovery, acid consumption, and greenhouse gas emissions. The novel resin in moist mix (RIMM) process, which integrates ambient leaching and in situ ion exchange selective recovery, is shown to offer potential for sustainable values extraction from sub-economic resources. Furthermore, the review highlights the key innovation challenges and concomitant opportunities for enhanced critical battery metal recovery from complex laterite ores. Full article

This paper presents a case study on heap bioleaching at the Monywa copper mine in Myanmar. Through mineralogical characterization and leaching tests, specific heap bioleaching technologies were developed and implemented at the mine. These technologies include acidification and start-up of heap bioleaching without external acid addition, ore classification with process optimization, and selective inhibition of pyrite oxidation for acid/iron balance during heap bioleaching. The optimized heap bioleaching technologies implemented at the Monywa copper mine have reduced both capital and operating costs. These advantages are specifically reflected in the use of multi-lift pads for both heap bioleaching and final residue storage, optimized processing based on ore characteristics, and the implementation of a solution closed cycle process without the need for additional acid or neutralization. These findings demonstrate a cost-effective approach to heap bioleaching and provide practical insights for operational optimization in similar copper mines. Full article

Heap leaching of copper is faced with a complex set of challenges, including mineral heterogeneity, the formation of passivating species, and the need to regulate critical variables such as pH, redox potential (Eh), oxidant concentration, and irrigation rate. If these factors are not properly managed, copper recovery is reduced, and significant environmental impacts may be generated, highlighting the urgency for systematic and sustainable approaches. To address this challenge, a systematic literature review (SLR) was conducted, screening 2344 documents and selecting 106 primary sources to analyze operational drivers and environmental considerations. Statistical methodologies (factorial designs, response surface methodology), multiscale modeling, and laboratory column tests were used to validate key variables, including pH (1.5–2.0), Eh (600–$750 \mathrm{mV}$), temperature (25–55 °C), irrigation rate (5–$15 \mathrm{L}/\left(\mathrm{h}·{\mathrm{m}}^2\right)$), acid concentration (0.5–$2.0 \mathrm{M}$), and emerging “green” reagents (e.g., glycine, organic surfactants). Precise control of these factors was found to reduce passivation, minimize fine-particle migration, and improve copper extraction up to 90%. The incorporation of oxidizing agents (e.g., Fe³⁺, H₂O₂) further accelerated mineral dissolution while preventing unwanted precipitates. In parallel, bioleaching strategies maintained high recoveries with lower chemical demand. Reviews of pilot studies confirmed the scalability of these optimized conditions, emphasizing both sustainability and cost-effectiveness. Full article

Heap bioleaching is considered to be a less energy-intensive metal-extraction technique compared to other methods, making it particularly attractive for low-grade sulfide ores. It has been successfully applied to recovery of copper, gold, and uranium from ores over decades. Despite its seemingly straightforward nature, heap bioleaching can experience failures if the ore is unsuitable or the heap leach process is not thoroughly investigated and well-developed. Therefore, multidisciplinary approaches are essential for research and development in heap bioleaching, as its performance depends on numerous processes operating across a wide range of length scales. This review focused on the current state of knowledge regarding the understanding of multi-scale mechanisms in heap bioleaching and the use of multidisciplinary approaches at different scales to develop the process. The investigation covered various scales, such as atomic and molecular, mineralogy and microbes, reaction particles, heap bioleaching units and full-scale factory production. Different approaches were employed to gain a comprehensive understanding of the microbial molecular structure and metabolism, the structure and reaction of minerals, microbial–mineral interaction, particles and aggregation states, and multiphase flow transfer, as well as laboratory experiments, modeling, industrialization, and operation optimization. We emphasized the need for collaboration among researchers from different disciplines and stress the importance of considering the coupling effects of physical, chemical, and microbiological factors when running heap bioleaching plants. Such collaboration and coupling are vital for successful implementation and optimization of heap bioleaching processes. This paper aimed to provide a comprehensive overview of current research related to heap bioleaching at different scales and disciplines, and gave implications to heap bioleaching technology development. Full article

Hydrodynamic hysteresis exists widely in agglomerated heaps with well-developed intra-pores, and it directly affects solute transports and bioleaching reaction. In this paper, the dynamic liquid retention behavior under different heap porosity and irrigation condition is quantified via a novel real-time, in-situ liquid retention characterizing system (RILRCS), and the potential effects of initial liquid retention on solute transport and leaching reaction are carefully discussed. The results show that the immobile liquid is dominant in agglomerated heaps. The ratio of immobile and mobile liquid (η) dynamically changes due to mineral dissolution and new flow path appearances. The η normally increases and mobile liquid occupies a higher proportion due to acidic leaching reactions, especially at a smaller R_g (10.32 mm) and a larger u (0.10 mm/s). The dynamic liquid retention is more sensitive to the diameter of packed feeds (R_g) and superficial flow rate (u) instead of leaching reactions. This might be because the damage of leaching reaction on minerals pores/voids is limited and cannot extensively change the potential pore channels or fluid flow paths. Based on pulse tracing and conductivity tests, we reveal that the solute resides longer under a slower u and smaller packed R_g condition, which corresponds well with desirable copper leaching efficiency. Specifically, the liquid hysteresis behavior is more obvious at a lower u (0.01 mm/s) and smaller R_g (10.32 mm). This paper gives a good reference to ascertain the liquid retention and hydrodynamic hysteresis and promote mineral leaching performance. Full article

Sulfuric acid solution containing ferric iron is the extractant for industrial heap bioleaching of copper sulfides. To start a heap bioleaching plant, sulfuric acid is usually added to the irrigation solution to maintain adequate acidity (pH 1.0–2.0) for copper dissolution. An industrial practice of heap bioleaching of secondary copper sulfide ore that began with only water irrigation without the addition of sulfuric acid was successfully implemented and introduced in this manuscript. The mineral composition and their behavior related to the production and consumption of sulfuric acid during the bioleaching in heaps was analyzed. This indicated the possibility of self-generating of sulfuric acid in heaps without exogenous addition. After proving by batches of laboratory tests, industrial measures were implemented to promote the sulfide mineral oxidation in heaps throughout the acidifying stages, from a pH of 7.0 to 1.0, thus sulfuric acid and iron was produced especially by pyrite oxidation. After acidifying of the heaps, adapted microbial consortium was inoculated and established in a leaching system. The launch of the bioleaching heap and finally the production expansion were realized without the addition of sulfuric acid, showing great efficiency under low operation costs. Full article

The feasibility of processing low-grade copper-nickel ores by heap bioleaching was investigated. It was found that an iron-oxidizing strain of acidophilic microorganisms, Acidithiobacillus ferrivorans, is effective in the leaching of sulfide ores from the deposits in Russia’s Murmansk region. Sulfide mineralization of the studied mineral feeds was described using the methods of X-ray phase analysis and optical microscopy. In the process of leaching, the pH and Eh values and the concentrations of ferric and ferrous iron, nickel, and copper ions were monitored. By the end of the experiment, 16.5% of nickel and 7.5% of copper was recovered from the ore of the Allarechensk technogenic deposit, while 22.5% of nickel and 12.7% copper were recovered from the ore of the Nud II deposit. By silicate analysis of the solid phase, patterns of ore chemistry change were described during the process of bioleaching. Full article

In the actual mining scenario, copper bioleaching, mainly raw mined material known as run-of-mine (ROM) copper bioleaching, is the best alternative for the treatment of marginal resources that are not currently considered part of the profitable reserves because of the cost associated with leading technologies in copper extraction. It is foreseen that bioleaching will play a complementary role in either concentration—as it does in Minera Escondida Ltd. (MEL)—or chloride main leaching plants. In that way, it will be possible to maximize mines with installed solvent-extraction and electrowinning capacities that have not been operative since the depletion of their oxide ores. One of the main obstacles for widening bioleaching technology applications is the lack of knowledge about the key events and the attributes of the technology’s critical events at the industrial level and mainly in ROM copper bioleaching industrial operations. It is relevant to assess the bed environment where the bacteria–mineral interaction occurs to learn about the limiting factors determining the leaching rate. Thus, due to inability to accurately determine in-situ key variables, their indirect assessment was evaluated by quantifying microbial metabolic-associated responses. Several candidate marker genes were selected to represent the predominant components of the microbial community inhabiting the industrial heap and the metabolisms involved in microbial responses to changes in the heap environment that affect the process performance. The microbial community’s predominant components were Acidithiobacillus ferrooxidans, At. thiooxidans, Leptospirillum ferriphilum, and Sulfobacillus sp. Oxygen reduction, CO₂ and N₂ fixation/uptake, iron and sulfur oxidation, and response to osmotic stress were the metabolisms selected regarding research results previously reported in the system. After that, qPCR primers for each candidate gene were designed and validated. The expression profile of the selected genes vs. environmental key variables in pure cultures, column-leaching tests, and the industrial bioleaching heap was defined. We presented the results obtained from the industrial validation of the marker genes selected for assessing CO₂ and N₂ availability, osmotic stress response, as well as ferrous iron and sulfur oxidation activity in the bioleaching heap process of MEL. We demonstrated that molecular markers are useful for assessing limiting factors like nutrients and air supply, and the impact of the quality of recycled solutions. We also learned about the attributes of variables like CO₂, ammonium, and sulfate levels that affect the industrial ROM-scale operation. Full article

In heap (bio)leaching processes, a substantial fraction of the valuable mineral is positioned below the ore particle surface. X-ray micro-computed tomography (μCT) was used to quantify the effect of ore type and structure and operating temperature on the leaching of this mineral, to investigate the rate-controlling factors. Mini-leaching columns containing agglomerated chalcopyrite, pyrite, and malachite ores were scanned by X-ray μCT (13.40 µm resolution) at select time intervals. The leaching of a relatively porous malachite ore was reaction-controlled, with no leaching penetration limitation into the ore particles. For two less porous ore types, the structure and higher porosity of the agglomerate rim and conditions that resulted in the degradation of the full ore matrix structure were found to be the determining variables of the leaching extent and time. In the case of a chalcopyrite ore, an enhancement of copper recovery and sulphide mineral dissolution with increasing temperature was attributable to the increased leaching penetration distance and crack development in addition to thermodynamically expected increased leaching rate. Increasing temperature did not affect the maximum penetration distance for the waste rock containing pyrite, with no crack development observed. Overall increases in iron recovery were due to accelerated leaching rates, though diffusion or mineral access limitations were evident at a higher temperature. Full article

Mining waste rocks containing sulfide minerals naturally provide the habitat for iron- and sulfur-oxidizing microbes, and they accelerate the generation of acid mine drainage (AMD) by promoting the oxidation of sulfide minerals. Sulfate-reducing bacteria (SRB) are sometimes employed to treat the AMD solution by microbial-induced metal sulfide precipitation. It was attempted for the first time to grow SRB directly in the pyritic heap bioleaching residue to compete with the local iron- and sulfur-oxidizing microbes. The acidic SRB and iron-reducing microbes were cultured at pH 2.0 and 3.0. After it was applied to the acidic heap bioleaching residue, it showed that the elevated pH and the organic matter was important for them to compete with the local bioleaching acidophiles. The incubation with the addition of organic matter promoted the growth of SRB and iron-reducing microbes to inhibit the iron- and sulfur-oxidizing microbes, especially organic matter together with some lime. Under the growth of the SRB and iron-reducing microbes, pH increased from acidic to nearly neutral, the Eh also decreased, and the metal, precipitated together with the microbial-generated sulfide, resulted in very low Cu in the residue pore solution. These results prove the inhibition of acid mine drainage directly in situ of the pyritic waste rocks by the promotion of the growth of SRB and iron-reducing microbes to compete with local iron and sulfur-oxidizing microbes, which can be used for the source control of AMD from the sulfidic waste rocks and the final remediation. Full article

Municipal solid waste incineration bottom ash (MSWI BA) is the main output of the municipal solid waste incineration process, both in mass and volume. It contains some heavy metals that possess market value, but may also limit the utilization of the material. This study illustrates a robust and simple heap leaching method for recovering zinc and copper from MSWI BA. Moreover, the effect of autotrophic and acidophilic bioleaching microorganisms in the system was studied. Leaching yields for zinc and copper varied between 18–53% and 6–44%, respectively. For intensified copper dissolution, aeration and possibly iron oxidizing bacteria caused clear benefits. The MSWI BA was challenging to treat. The main components, iron and aluminum, dissolved easily and unwantedly, decreasing the quality of pregnant leach solution. Moreover, the physical nature and the extreme heterogeneity of the material caused operative requirements for the heap leaching. Nevertheless, with optimized parameters, heap leaching may offer a proper solution for MSWI BA treatment. Full article

The aim was to study the bioleaching performance of chemoheterotrophic bacterium involved in leaching of major, rare earth, and radioactive elements from red mud (RM), and to explore the underlying mechanism. An acid-producing bacterium, identified as Acetobacter sp., was isolated from RM impoundment and used in the bioleaching experiments under one-step, two-step and spent medium process at up to 10% pulp density. The results showed that the leaching ratios of Al, Lu, Y, Sc, and Th were 55%, 53%, 61%, 52%, and 53% respectively under one-step process at 2% pulp density. Under both one- and two-step processes at 2% pulp density, the radioactivity of bioleached RM can meet the relevant regulation in China. The total amount of organic acids excreted by Acetobacter sp. increased with an increase of RM pulp density. After bioleaching, contents of hematite and gibbsite decreased but perovskite increased in RM. Micromorphology analysis indicated that the cells of Acetobacter sp. adhered to RM particles and formed large-size aggregates, and a new crystal of weddellite emerged. In view of the shorter lag phase and smaller biomass comparing to fungi even under direct contact with RM, bacterium Acetobacter sp. is supposed to apply to in situ heap or dump bioleaching of RM. Full article

The commercial application of copper bioleaching, an environmentally-friendly approach for low-grade and secondary mineral resources recycling, has increased worldwide since the 2000s. As the world’s second-largest economic entity and the largest developing country, China has the largest demand for metal resources, significantly advancing the theory and industrial technology of copper bioleaching. This paper reviews the exploration and application of copper bioleaching in China. Two typical bioleaching applications and technological processes, bioheap leaching at the Zijinshan Copper Mine and bioheap leaching at the Dexing Copper Mine, are introduced. The considerable research completed by researchers is summarized, especially focusing on the isolation and identification of leaching bacteria, the bioleaching mechanism and interface reactions, multistage percolation behavior, bioleaching system reconstruction, the multiphysics coupled model, and enhanced copper bioleaching from waste printed circuit boards (WPCBs). Based on this investigation in China, key trends and prospects in copper bioleaching—such as efficiency improvement, environmental protection, and improved technology applications—are proposed. Full article

At the industrial scale, bioleaching of metal sulfides includes two main technologies, tank leaching and heap leaching. Fluctuations in temperature caused by the exothermic reactions in a heap have a pronounced effect on the growth of microbes and composition of mixed microbial populations. Currently, little is known on the influence of pre-colonized mesophiles or moderate thermophiles on the attachment and bioleaching efficiency by thermophiles. The objective of this study was to investigate the interspecies interactions of the moderate thermophile Sulfobacillus thermosulfidooxidans DSM 9293^T and the thermophile Acidianus sp. DSM 29099 during initial attachment to and dissolution of pyrite. Our results showed that: (1) Acidianus sp. DSM 29099 interacted with S. thermosulfidooxidans^T during initial attachment in mixed cultures. In particular, cell attachment was improved in mixed cultures compared to pure cultures alone; however, no improvement of pyrite leaching in mixed cultures compared with pure cultures was observed; (2) active or inactivated cells of S. thermosulfidooxidans^T on pyrite inhibited or showed no influence on the initial attachment of Acidianus sp. DSM 29099, respectively, but both promoted its leaching efficiency; (3) S. thermosulfidooxidans^T exudates did not enhance the initial attachment of Acidianus sp. DSM 29099 to pyrite, but greatly facilitated its pyrite dissolution efficiency. Our study provides insights into cell-cell interactions between moderate thermophiles and thermophiles and is helpful for understanding of the microbial interactions in a heap leaching environment. Full article

Bioleaching is the mobilization of metal cations from insoluble ores by microorganisms. Biofilms can enhance this process. Since Sulfobacillus often appears in leaching heaps or reactors, this genus has aroused attention. In this study, biofilm formation and subsequent pyrite dissolution by the Gram-positive, moderately thermophilic acidophile Sulfobacillus thermosulfidooxidans were investigated. Five strategies, including adjusting initial pH, supplementing an extra energy source or ferric ions, as well as exchanging exhausted medium with fresh medium, were tested for enhancement of its biofilm formation. The results show that regularly exchanging exhausted medium leads to a continuous biofilm development on pyrite. By this way, multiply layered biofilms were observed on pyrite slices, while only monolayer biofilms were visible on pyrite grains. In addition, biofilms were proven to be responsible for pyrite leaching in the early stages. Full article