Bioleaching of spent refinery catalysts: A review

Iron bioleaching and polymers accumulation by an extreme acidophilic bacterium

In many European regions, both local metallic and non-metallic raw materials are poorly exploited due to their low quality and the lack of technologies to increase their economic value. In this context, the development of low cost and eco-friendly approaches, such as bioleaching of metal impurities, is crucial. The acidophilic strain Acidiphilium sp. SJH reduces Fe(III) to Fe(II) by coupling the oxidation of an organic substrate to the reduction of Fe(III) and can therefore be applied in the bioleaching of iron impurities from non-metallic raw materials. In this work, the physiology of Acidiphilium sp. SJH and the reduction of iron impurities from quartz sand and its derivatives have been studied during growth on media supplemented with various carbon sources and under different oxygenation conditions, highlighting that cell physiology and iron reduction are tightly coupled. Although the organism is known to be aerobic, maximum bioleaching performance was obtained by cultures cultivated until the exponential phase of growth under oxygen limitation. Among carbon sources, glucose has been shown to support faster biomass growth, while galactose allowed highest bioleaching. Moreover, Acidiphilium sp. SJH cells can synthesise and accumulate Poly-β-hydroxybutyrate (PHB) during the process, a polymer with relevant application in biotechnology. In summary, this work gives an insight into the physiology of Acidiphilium sp. SJH, able to use different carbon sources and to synthesise a technologically relevant polymer (PHB), while removing metals from sand without the need to introduce modifications in the process set up.

Techno-economic assessment of bioleaching for metallurgical by-products

This study focused on the economic feasibility of two potential industrial-scale bioleaching technologies for metal recovery from specific metallurgical by-products, mainly basic oxygen steelmaking dust (BOS-D) and goethite. The investigation compared two bioleaching scaling technology configurations, including an aerated bioreactor and an aerated and stirred bioreactor across different scenarios. Results indicated that bioleaching using Acidithiobacillus ferrooxidans proved financially viable for copper extraction from goethite, particularly when 5% and 10% pulp densities were used in the aerated bioreactor, and when 10% pulp density was used in the aerated and stirred bioreactor. Notably, a net present value (NPV) of $1,275,499k and an internal rate of return (IRR) of 65% for Cu recovery from goethite were achieved over 20-years after project started using the aerated and stirred bioreactor plant with a capital expenditure (CAPEX) of $119,816,550 and an operational expenditure (OPEX) of $5,896,580/year. It is expected that plant will start to make profit after one year of operation. Aerated and stirred bioreactor plant appeared more reliable alternative compared to the aerated bioreactor plant as the plant consists of 12 reactors which can allow better management and operation in small volume with multiple reactors. Despite the limitations, this techno-economic assessment emphasized the significance of selective metal recovery and plant design, and underscored the major expenses associated with the process.

Recovery of nickel and preparation of ferronickel alloy from spent petroleum catalyst via cooperative smelting-vitrification process with coal fly ash

Spent petroleum catalyst (SPC) is a highly toxic material since it contains heavy metals and hazardous substances. A novel recycling technology based on the cooperative smelting-vitrification process by using coal fly ash (CFA) as a fluxing material was proposed. The benefits of employing CFA in this cooperative smelting-vitrification process of SPC have been demonstrated via the results of lab-scale and scale-up experiments. The experimental results indicated that with a collector iron (Fe) addition of 26 wt%, a C/O molar ration of 1.4, and an H3BO3 addition of 14 wt%, the maximum nickel (Ni) recovery was ∼98% by controlling the CFA addition of 40-50 wt%, basicity of 0.4-0.5, smelting temperature of 1550°C, and smelting time of 60 min, respectively. In this process, a ferronickel (Ni-Fe) alloy with a high Ni grade of 10 wt% was successfully obtained, which could be directly further produced stainless steel. Meanwhile, a glass slag with a low Ni content (below 0.12 wt%) was also obtained, and its leaching characteristics further confirmed it is a non-hazardous slag because heavy metals were successfully encapsulated in glass slag, and thereby, this proposed method achieved the transformation from hazardous solid waste to general solid waste. The results of the 10 kg scale-up experiment indicated the possibility of industrialization of this new technology. Therefore, the process proposed in this study is a practical and promising process for Ni recovery from SPC and reutilization of CFA.

Extraction of platinum group metals from catalytic converters

Platinum group metals (PGMs) assume an important role within the chemistry and chemical engineering due to their exceptional chemical stability in high temperatures and various environmental conditions. Their unique attributes make them highly demanded materials across an array of industries. Nevertheless, the gradual depletion of PGM reserves underscores necessitates of recycling PGM-containing waste as a means to ensure the reasonable utilization of resources. Recycling of catalytic waste, in particular, presents a more cost-effective and environmentally sustainable approach acquiring these metals, in contrast to the conventional practice of mining from natural ores. Of particular importance are spent automotive catalysts, which represent a valuable source of platinum group metals, featuring substantially higher PGM concentrations than their naturally occurring counterparts. Conventionally, the recovering of PGMs from waste materials predominantly employs hydrometallurgical and pyrometallurgical processes. Unfortunately, these established techniques entail the utilization of potent oxidizing acidic solutions, including aqua regia and hydrochloric acid with chlorine gas, which exert adverse ecological consequences. In recent years, there has been a growing focus on the development of alternative methodologies that are both environmentally friendly and economically viable for the recovery of PGMs from spent catalysts. Notable among these emerging techniques are solvometallurgy, molecular recognition technology, and magnetic separation. This comprehensive review endeavors to study and assess the latest advancements in the recovery of platinum group metals from spent catalysts, meticulously evaluating their respective advantages and disadvantages. Through an analysis, this review aspires to identify the most promising method - one that combines environmental friendliness and economic feasibility.

Recovery of precious metals from waste printed circuit boards though bioleaching route: A review of the recent progress and perspective

The rapid proliferation of electronic waste (e-waste), including waste printed circuit boards (WPCBs), has exerted immense pressure on the environment. The recovery of precious metals from WPCBs not only serves as an effective means of alleviating this environmental burden but also generates economic value. This review focuses on bioleaching, an environmentally friendly method for extracting precious metals from WPCBs. Under various conditions, this method has achieved leaching rates of 30%-73% for Au and 33.8%-90% for Ag. However, there is a relative scarcity of studies on the bioleaching of precious metals from WPCBs. In this paper, we provide an overview of the current status of bioleaching for precious metals from WPCBs and describe the underlying mechanisms. We also briefly outline the influence of various process factors on leaching efficiency. While this review underscores the considerable potential of bioleaching in WPCBs applications, certain limitations hinder the engineering-scale application of the technology. Consequently, this paper describes the current enhanced processes for enhancing leaching efficiency. Overall, this review can serve as a valuable reference for future research endeavors, ultimately promoting the widespread utilization of bioleaching for the recovery of precious metals from WPCBs.

Review on the gentle hydrometallurgical treatment of WPCBs: Sustainable and selective gradient process for multiple valuable metals recovery

The metal resource crisis and the inherent need for a low-carbon circular economy have driven the rapid development of e-waste recycling technology. High-value waste printed circuit boards (WPCBs) are an essential component of e-waste. However, WPCBs are considered hazardous to the ecosystem due to the presence of heavy metals and brominated organic polymers. Therefore, achieving the recycling of metals in WPCBs is not only a strategic requirement for building a green ecological civilization but also an essential guarantee for achieving a safe supply of mineral resources. This review systematically analyzes the hydrometallurgical technology of metals in WPCBs in recent years. Firstly, the different unit operations of pretreatment in the hydrometallurgical process, which contain disassembly, crushing, and pre-enrichment, were analyzed. Secondly, environmentally friendly hydrometallurgical leaching systems and high-value product regeneration technologies used in recent years to recover metals from WPCBs were evaluated. The leaching techniques, including cyanidation, halide, thiourea, and thiosulfate for precious metals, and inorganic acid, organic acid, and other leaching methods for base metals such as copper and nickel in WPCBs, were outlined, and the leaching performance and greenness of each leaching system were summarized and analyzed. Eventually, based on the advantages of each leaching system and the differences in chemical properties of metals in WPCBs, an integrated and multi-gradient green process for the recovery of WPCBs was proposed, which provides a sustainable pathway for the recovery of metals in WPCBs. This paper provides a reference for realizing the gradient hydrometallurgical recovery of metals from WPCBs to promote the recycling metal resources.

Unlocking the hidden value of industrial by-products: Optimisation of bioleaching to extract metals from basic oxygen steelmaking dust and goethite

In this study, the potential of bioleaching to extract valuable metals from industrial by-products, specifically basic oxygen steelmaking dust (BOS-D) and goethite was investigated. These materials are typically discarded due to their high zinc content and lack of efficient regeneration processes. By using Acidithiobacillus ferrooxidans, successful bioleaching of various metals, including heavy metals, critical metals, and rare earth elements was achieved. The Taguchi orthogonal array design was used to optimise the bioleaching process, considering four variables at three different levels. After 14 days, the highest metal extraction for the BOS-D (11.2 mg Zn/g, 3.2 mg Mn/g, 1.6 mg Al/g, 0.0013 mg Y/g, and 0.0026 mg Ce/g) was achieved at 1% solid concentration, 1% energy source concentration, 1% inoculum concentration, and pH 1.5. For goethite, the optimal conditions were 1% solid concentration, 4% energy source concentration, 10% inoculum concentration, and pH 2 resulting in a extraction of 26.6 mg Zn/g, 2.1 mg/g Mn, 1.8 mg Al/g, 0.01 mg Co/g, 0.0022 mg Y/g. These findings are significant, as they demonstrate the potential to extract valuable metals from previously discarded industrial by-products. The extraction of such metals can have substantial economic and environmental implications, while simultaneously reducing waste in the metallurgical industry. Furthermore, the preservation of initial concentration of iron in both BOS-D and goethite residues represents a significant step towards implementing more sustainable industrial practices.

High-value utilisation of PGM-containing residual oil: Recovery of inorganic acids, potassium, and PGMs using a zero-waste approach

Residual oil containing platinum group metals (PGMs), which is under-researched, can easily pose resource waste and environmental risks. PGMs feature as scarce strategic metals, and inorganic acids and potassium salts are also considered valuable. An integrated process for the harmless treatment and recovery of useful resources from residual oil is proposed herein. This work developed a zero-waste process based on the study of the main components and characteristics of the PGM-containing residual oil. The process consists of three modules: pre-treatment for phase separation, liquid-phase resource utilisation, and solid-phase resource utilisation. Separating the residual oil into liquid and solid phases allows for the maximum recovery of valuable components. However, concerns about the accurate determination of valued components emerged. Findings revealed that Fe and Ni are highly susceptible to spectral interference in the PGMs test when using the inductively coupled plasma method. After studying 26 PGM emission lines, Ir 212.681 nm, Pd 342.124 nm, Pt 299.797 nm, and Rh 343.489 nm were reliably identified. Finally, formic acid (81.5 g/t), acetic acid (117.2 kg/t), propionic acid (291.9 kg/t), butyric acid (3.6 kg/t), potassium salt (553.3 kg/t), Ir (27.8 g/t), Pd (10960.0 g/t), Pt (193.1 g/t), and Rh (109.8 g/t) were successfully obtained from the PGM-containing residual oil. This study provides a helpful reference for the determination of PGM concentrations and high-value utilisation of PGM-containing residual oil.

Biological approaches for E-waste management: A green-go to boost circular economy

E-waste is a pressing situation on human due to its complex composition. Although E-waste on one hand has some toxic components but at the same time, it would be a promising business sector. Recycling of E-waste to mine-out valuable metals and other components has opened a chance of business and hence a way towards transformation of linear economy to circular one. Chemical, physical and traditional technologies are holding the position in E-waste recycling sector but sustainability with respect to cost and environmental issues is a major concern associated with these technologies. In order to overcome these gaps, lucrative, environment friendly and sustainable technologies need to be implied. Biological approaches could be a green and clean approach to handle E-waste through sustainable and cost-effective means by considering socio-economic and environmental aspects. This review elaborates biological approaches for E-waste management and advancements in expanse. The novelty covers the environmental and socio-economic impacts of E-waste, solution and further scope of biological approaches, further research and development need in this contour to come up with sustainable recycling process.

Fungal biotechnology for urban mining of metals from waste printed circuit boards: A review

Rapid surge in electronic waste (e-waste) and its unscientific handling has an adverse impact on humans and the environment. Waste printed circuit board (WPCB), an integrated component of e-waste, has a high metallic content that includes both toxic and precious metals. Therefore, metal recovery is essential not just to avoid environmental degradation but also for economic growth. The current literature analysis focuses on one such eco-friendly approach, known as fungal biotechnology, for extracting metals from WPCBs. Among diverse bioleaching agents, fungi have shown promising metal extraction efficiency (Al: 65-96%; Co: 45-90%; Cu: 34-100%; Ni: 8-95%; Mn: 70-95%; Pb: 27-95%; Zn: 54-99%) and the ability to work in a wide pH range. However, in terms of metal recovery from WPCBs, fungal bioleaching has been less explored. This review, thus, assesses the fungal biotechnology for metal extraction from WPCBs and discusses the associated mechanism and kinetics involved. Different process parameters affecting the fungal bioleaching have also been discussed briefly. The review highlights that, while this process has enough potential, some associated drawbacks hinder its practical applicability on an industrial scale. Lastly, some suggestions for scaling up and reducing the cost of the process have been made, which need to be addressed.

Utilization of amino acid for selective leaching of critical metals from spent hydrodesulfurization catalyst

While spent catalysts can cause serious environmental pollution, they can be considered an essential secondary metal source due to their high critical metal grades. The formation of the amino acid-metal complex is often seen in nature, and its potential application in hydrometallurgy can be foreseen. Alanine (Ala) was first screened as the most effective type of amino acid to be used for the selective leaching of spent hydrodesulfurization catalyst (consisting of MoS₂ and Co₃S₄ supported on Al₂O₃, at 10% Mo and 2.4% Co grades). The sequential 3-step leaching (Step-1: Alkaline Ala leaching at 45°C, Step-2: Hot water leaching at 70°C, Step-3: Second alkaline Ala leaching at 45°C) was conducted where the role of Ala was found to be at least three-fold; 1) maintaining alkalinity by amino acid’s buffering capacity to assist Mo leaching, 2) selectively precipitating Co by forming Co-Ala complex with a distinctive pink color, which can readily re-dissolve in hot water to be separated from spent catalyst particles. 3) Effectively suppressing unwanted dissolution of Al throughout the reaction without needing pH control. Consequently, highly metal-selective, two separate Co-rich (<1% Mo and 79% Co dissolved, Al not detected) and Mo-rich (96% Mo, 19% Co, and 2.1% Al dissolved) leachates were obtained. This study highlighted the potential utility of amino acids as non-toxic, alternative metal lixiviant as well as a metal precipitant for selective leaching of critical metals from spent hydrodesulfurization catalyst.

Enhanced metal bioleaching mechanisms of extracellular polymeric substance for obsolete LiNixCoyMn1-x-yO2 at high pulp density

Harmful chemicals present in electric vehicle Li-ion batteries (EV LIBs) can limit the pulp density of bioleaching processes using Acidithiobacillus sp. to 1.0% (w/v) or lower. The strong enhancing mechanisms of extracellular polymeric substances (EPS) on the bioleaching of metals from spent EV LIBs at high pulp density (4% w/v) were studied using bio-chemical, spectroscopic, surface structure imaging and bioleaching kinetic methods. Results demonstrated that the added EPS significantly improved bioleaching efficiency of Ni, Co and Mn improved by 42%, 40% and 44%, respectively. EPS addition boosted the growth of cells under adverse conditions to produce more biogenic H⁺ while Fe³⁺ and Fe²⁺ were adsorbed by the biopolymer. This increased Li extraction by acid dissolution and concentrated the Fe³⁺/Fe²⁺ cycle via non-contact mechanisms for the subsequent contact bioleaching of Ni, CO and Mn at the EV LIB-bacteria interface. During the leaching process, added EPS improved adhesion of the bacterial cells to the EV LIBs, and the resultant strong interfacial reactions promoted bioleaching of the target metals. Hence, a combination of non-contact and contact mechanisms initiated by the addition of EPS enhanced the bioleaching of spent EV LIBs at high pulp density.

Bioleaching of Typical Electronic Waste-Printed Circuit Boards (WPCBs): A Short Review

The rapid pace of innovations and the frequency of replacement of electrical and electronic equipment has made waste printed circuit boards (WPCB) one of the fastest growing waste streams. The frequency of replacement of equipment can be caused by a limited time of proper functioning and increasing malfunctions. Resource utilization of WPCBs have become some of the most profitable companies in the recycling industry. To facilitate WPCB recycling, several advanced technologies such as pyrometallurgy, hydrometallurgy and biometallurgy have been developed. Bioleaching uses naturally occurring microorganisms and their metabolic products to recover valuable metals, which is a promising technology due to its cost-effectiveness, environmental friendliness, and sustainability. However, there is sparse comprehensive research on WPCB bioleaching. Therefore, in this work, a short review was conducted from the perspective of potential microorganisms, bioleaching mechanisms and parameter optimization. Perspectives on future research directions are also discussed.

Insights into the polysaccharides and proteins production from Penicillium citrinum during bioleaching of spent coin cells

The essential role of polysaccharides and proteins of extracellular polymeric substances (EPS) has been well known in the bioleaching process. However, there is no information on the role of these compositions in the bioleaching of spent coin cells (SCCs). This study investigated protein and polysaccharide production as biological macromolecules during the bioleaching of SCCs at various pulp densities using adapted Penicillium citrinum. The adaptation improved the tolerance index of fungi for the bioleaching up to a pulp density of 30 g/L. The EPS analysis indicated that loosely bound EPS (LB-EPS) contained a high concentration of polysaccharides. Instead, the most protein content was concentrated at tightly bound EPS (TB-EPS). Both protein and polysaccharide keep growing up to 20 g/L of pulp density during the entire period of bioleaching, and the maximum binding rate of Mn and Li to EPS was 43% and 15%, respectively. Pearson correlation indicated the positive correlation of the protein and the polysaccharides content on bioleaching efficiencies. From the FTIR spectroscopy, the principal functional groups on Mn and Li binding were OH and carboxyl. The FE-SEM analysis revealed the deformation of EPS at 30 g/L of pulp density, which suggested the toxic effect of this pulp density.

Accessing Metals from Low-Grade Ores and the Environmental Impact Considerations: A Review of the Perspectives of Conventional versus Bioleaching Strategies

Mining has advanced primarily through the use of two strategies: pyrometallurgy and hydrometallurgy. Both have been used successfully to extract valuable metals from ore deposits. These strategies, without a doubt, harm the environment. Furthermore, due to decades of excessive mining, there has been a global decline in high-grade ores. This has resulted in a decrease in valuable metal supply, which has prompted a reconsideration of these traditional strategies, as the industry faces the current challenge of accessing the highly sought-after valuable metals from low-grade ores. This review outlines these challenges in detail, provides insights into metal recovery issues, and describes technological advances being made to address the issues associated with dealing with low-grade metals. It also discusses the pragmatic paradigm shift that necessitates the use of biotechnological solutions provided by bioleaching, particularly its environmental friendliness. However, it goes on to criticize the shortcomings of bioleaching while highlighting the potential solutions provided by a bespoke approach that integrates research applications from omics technologies and their applications in the adaptation of bioleaching microorganisms and their interaction with the harsh environments associated with metal ore degradation.

Sequential-Anaerobic and Sequential-Aerobic Bioleaching of Metals (Ni, Mo, Al and V) from Spent Petroleum Catalyst in Stirred Tank Batch Reactor: A Comparative Study

Spent petroleum catalyst as a repository of several toxic metals is recommended for metal removal before safe disposal. To evaluate an effective biotechnological approach for metal removal, a comparative study between sequential-aerobic and sequential-anaerobic bioleaching processes was conducted for the removal of metals from crushed-acetone-pretreated spent petroleum catalyst. The SEM-EDX and XPS analysis confirmed the presence of Ni, Al, Mo and V in their oxidic and sulphidic forms in spent catalyst. The bioleaching experiments were performed in stirred tank batch reactors (2.5 L), temperature 30 °C, pH 1.4 and stirring speed 250 rpm for the period of 160 h. Sulfuric acid acted as lechant for both sequential-aerobic (Acidithiobacillus ferrooxidans oxidised sulfur to sulfuric acid aerobically) and sequential-anaerobic (Acidithiobacillus ferrooxidans oxidised sulphur to sulfuric acid coupled with the ferric reduction to ferrous anaerobically) bioleaching studies. The higher Ni and V extractions compared to Al and Mo for all the studies were due to increased solubility of Ni and V, and supported by XPS which showed marginal signs of Ni and V peaks in leach residues compared to feed spent catalyst. At the end (320 h), sequential-aerobic bioleaching was resulted to 99% Ni, 65% Al, 90% Mo and 99% V extraction quite more effective than sequential-anaerobic bioleaching (88% Ni, 28% Al, 33% Mo and 77% V) and sequential-control leaching (94% Ni, 20% Al, 40% Mo and 57% V). Although anaerobic bioleaching a possible approach, aerobic condition was found to be more suitable for sulfuric acid generation by A. ferrooxidans and high yield. So aerobic bioleaching is recommended to be favourable approach compared to anaerobic counterpart for future study and extrapolation.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s12088-021-00978-8.

The smallest space miners: principles of space biomining

As we aim to expand human presence in space, we need to find viable approaches to achieve independence from terrestrial resources. Space biomining of the Moon, Mars and asteroids has been indicated as one of the promising approaches to achieve in-situ resource utilization by the main space agencies. Structural and expensive metals, essential mineral nutrients, water, oxygen and volatiles could be potentially extracted from extraterrestrial regolith and rocks using microbial-based biotechnologies. The use of bioleaching microorganisms could also be applied to space bioremediation, recycling of waste and to reinforce regenerative life support systems. However, the science around space biomining is still young. Relevant differences between terrestrial and extraterrestrial conditions exist, including the rock types and ores available for mining, and a direct application of established terrestrial biomining techniques may not be a possibility. It is, therefore, necessary to invest in terrestrial and space-based research of specific methods for space applications to learn the effects of space conditions on biomining and bioremediation, expand our knowledge on organotrophic and community-based bioleaching mechanisms, as well as on anaerobic biomining, and investigate the use of synthetic biology to overcome limitations posed by the space environments.

Copper and Zinc Recovery from Sulfide Concentrate by Novel Artificial Microbial Community

Exploring efficient methods to enhance leaching efficiency is critical for bioleaching technology to deal with sulfide concentrate. In our study, a novel artificial microbial community was established to augment the bioleaching efficiency and recovery of copper (Cu) and zinc (Zn). The optimum parameters in bioleaching experiments were explored according to compare a series of conditions from gradient experiments: the pH value was 1.2, temperature was 45 °C, and rotation speed was 160 r/min, which were different with pure microorganism growth conditions. Under optimal conditions, the result of recovery for Cu and Zn indicated that the average leaching rate reached to 80% and 100% respectively, which almost increased 1.8 times and 1.2 times more than control (aseptic condition) group. Therefore, this method of Cu and Zn recovery using a new-type artificial microbial community is expected to be an environmentally-friendly and efficient bioleaching technology solution, which has the potential of large-field engineering application in the future.

Spent sulfuric acid plant catalyst: valuable resource of vanadium or risky residue? Process comparison for environmental implications

The enormous amount of spent catalysts generated worldwide may pose a risk to the environment because of their high load of metals, including vanadium. The latter may be mobilized and released to the environment if managed improperly. Moreover, the catalysts could be considered as secondary resources rather than waste. This study aimed at the efficient extraction of vanadium from spent desulfurization catalyst (SDC) from a sulfuric acid production plant. The raw SDC and the post-extraction residues were characterized in terms of their chemical and phase composition. The metal mobility from the materials was examined with both single-step and multi-step extractions. The environmental risk assessment was performed using sequential extraction. The study revealed that both tested methods (citric acid leaching and bioleaching with Acidithiobacillus thiooxidans) enable the extraction of nearly 96% of V from SDC with a simultaneous reduction of metal mobility. However, the bacterial treatment was found more suitable. The leached residue was mostly (> 90%) composed of SiO₂, which makes it a potential candidate for application in construction (e.g., concrete mixtures) after additional examinations. The study highlights the need to develop a metal extraction process for SDC in a way that metal-free residue could be a final product.

Bioleaching for environmental remediation of toxic metals and metalloids: A review on soils, sediments, and mine tailings

Owing to industrial evolution, a huge mass of toxic metals, including Co, Cu, Cr, Mn, Ni, Pb, and Zn, and metalloids, such as As and Sb, has inevitably been released into the natural environment and accumulated in soils or sediments. Along with modern industrialization, many mineral mines have been explored and exploited to provide materials for industries. Mining industries also generate a vast amount of waste, such as mine tailings, which contain a high concentration of toxic metals and metalloids. Due to the low economic status, a majority of mine tailings are simply disposed into the surrounding environments, without any treatment. The mobilization and migration of toxic metals and metalloids from soils, sediments, and mining wastes to water systems via natural weathering processes put both the ecological system and human health at high risk. Considering both economic and environmental aspects, bioleaching is a preferable option for removing the toxic metals and metalloids because of its low cost and environmental safety. This chapter reviews the recent approaches of bioleaching for removing toxic metals and metalloids from soils, sediments, and mining wastes. The comparison between bioleaching and chemical leaching of various waste sources is also discussed in terms of efficiency and environmental safety. Additionally, the advanced perspectives of bioleaching for environmental remediation with consideration of other influencing factors are reviewed for future studies and applications.

Optimization of zinc bioleaching from paint sludge using Acidithiobacillus thiooxidans based on response surface methodology

The reduction of zinc metal in the paint sludge, a hazardous waste, was investigated using Acidithiobacillus thiooxidans by a two-stage bioleaching process. This process was performed using the response surface methodology (RSM) method based on the central composite design (CCD). Four variables, a temperature range of 32-34.5-37 °C, rotation speed of shaker 120-150-180 rpm, pH of 4.2-3.2-2.2, and particle sizes of 1-2-3 mm, were used to optimize the experiments. The results showed that with a constant pulp density of 10 g/L at 32 °C, shaker speed of 120 rpm, a particle size of 1 mm and pH of 4.2, the highest removal predicted by the software (Design Expert version 11) was 22.89%. Repeating the experiments confirmed a decrease in zinc to the nearest predicted point. According to the ANOVA result, the rotation speed of the shaker has the greatest effect on the bioleaching process, followed by the two variables of the rotation speed of shaker and pH together affects. After the bioleaching process, energy dispersive X-ray (EDX) and mapping analysis showed quantitative changes in the chemical composition of the paint sludge, and morphological changes of texture were confirmed by scanning electron microscopy (SEM).

Bioleaching of copper and nickel from mobile phone printed circuit board using Aspergillus fumigatus A2DS

The recovery of metals from electronic waste was investigated by using fungal strain Aspergillus fumigatus A2DS, isolated from the mining industry wastewater. Fifty-seven percent of copper and 32% of nickel were leached (analyzed by Inductively Coupled Plasma Atomic Emission Spectroscopy (ICP-OES)) by the organism after one-step leaching at a temperature of 30 °C (shaking condition for 7 days). Maximum % of copper and nickel were obtained at a pH of 6 (58.7% Cu and 32% Ni), the temperature of 40 °C (61.8% Cu and 27.07% Ni), a pulp density of 0.5% (62% Cu and 42.37% Ni), and inoculums of 1% (58% Cu and 32.29% Ni). The XRD pattern of PCB showed 77.6% of copper containing compounds. XRD analysis of the leachate residue showed only 23.2% Euchorite (ASCu2H7O8) and 9.4% other copper containing compounds, indicating the leaching property of the fungus. HPLC analysis of the spent medium showed the presence of different acids like citric, succinic, and fumaric acid. The FTIR spectrum showed a decrease in carboxylic stretching in the leachate produced after bioleaching using spent medium. ICPOES of the leachate obtained using spent medium showed that 61% of the copper and 35% of nickel were leached out after seven days of incubation at shaking condition and 57% of copper and 32.8% of nickel at static condition confirming acidolysis property of the strain. A. fumigatus A2DS metal absorption and adsorption ability were observed using transmission electron microscopy (TEM) and scanning electron microscopy energy dispersive X-ray (SEM-EDX) respectively. The results thus indicate that bioleaching of Cu and Ni is bioleached by A. fumigatus A2DS.

Bioleaching metals from waste electrical and electronic equipment (WEEE) by Aspergillus niger: a review

In the twenty-first century, the increasing demand for electrical and electronic equipment (EEE) has caused its quick update and the shortening of its service life span. As a consequence, a large number of waste electrical and electronic equipment (WEEE) needs to be processed and recycled. As an environmentally friendly method, biometallurgy has received extensive attention in the disposal of WEEE in recent years. Aspergillus niger is an acid-producing fungus with a potential applicability to improve metals' recycling efficiency. This review article describes the latest statistical status of WEEE and presents the latest progress of various metallurgical methods involved in WEEE recycling for metal recovery. Moreover, based on the summary and comparison towards studies have been reported for bioleaching metals from WEEE by A. niger, the bioleaching mechanisms and the bioleaching methods are explained, as well as the effects of process parameters on the performance of the bioleaching process are also discussed. Some insights and perspectives are provided for A. niger to be applied to industrial processing scale.

Lithium bioleaching: An emerging approach for the recovery of Li from spent lithium ion batteries

The rapidly growing demand for lithium has resulted in a sharp increase in its price. This is due to the ubiquitous use of lithium-ion batteries (LIBs) in large-scale energy and transportation sectors as well as portable devices. Recycling of the LIBs for being the supply of critical metals hence becomes environmentally and economically viable. The presently used approaches for the recovery of spent LIBs like pyrometallurgical process can effectively recover nickel, cobalt, and copper, while lithium is usually lost in slag. Bioleaching process as an alternative method of extraction and recovery of valuable metals from the primary and secondary resources has been attracting a large pool of attraction. This method can provide higher recovery yield even for low concentration of metals which makes it viable among conventional methods. The bioleaching process can work with lower operating cost and consumed water and energy along with a simple condition, which produces less hazardous by-products ultimately. Here, we comprehensively review the biological and chemical mechanisms of the bioleaching process with a conclusive discussion to help how to extend the use of bioleaching for lithium extraction and recovery from the spent LIBs with a focus on recovery yields improvement. We elaborate on the three main types of the reported bioleaching with considering effective parameters including temperature, initial pH, pulp density, aeration, and medium and cell nutrients to sustain microorganism activity. Finally, practical challenges and future opportunities of lithium are discussed to inspire future research trends and pilot studies to realize the full potential of lithium recovery using sustainable bioleaching processes to extend a clean energy future.

Generation behavior of extracellular polymeric substances and its correlation with extraction efficiency of valuable metals and change of process parameters during bioleaching of spent petroleum catalyst

The vital functions of extracellular polymeric substances (EPS) have been well recognized in bioleaching of sulfide ores. However, no report is available about the role of EPS in bioleaching of spent catalyst. To completely and deeply understand the functions of EPS in bioleaching of spent catalyst, the generation behavior of EPS at various pulp densities during bioleaching was characterized by three-dimensional excitation-emission matrix (3DEEM), and its relevance with bioleaching performance and process parameters were analyzed using mathematical means. The results showed that the EPS contain humus-like substances as main component (>70%) and protein-like substances as minor component (<30%). Both total EPS and humus-like substances mainly keep growing over the whole duration of bioleaching at low pulp density of 5.0% or lower; whereas total EPS and humus-like fraction keep declining at high pulp density of 7.5% or higher. Among the total EPS and its components, humus-like substances only have a positive significant correlation with bioleaching efficiencies of both Co and Mo and affect bioleaching process more greatly due to greater correlation coefficient. Biofilm appears at the spent catalyst surface under 2.5% of pulp density mediated by EPS while no biofilm occurs at 10% of pulp density due to shortage of EPS, accounting for the great difference in bioleaching efficiencies between high and low pulp densities which are 48.3% for Mo and 50.0% for Co at 10% of pulp density as well as 75.9% for Mo and 78.8% for Co at 2.5% of pulp density, respectively.

Effect of pulp density on the bioleaching of metals from petroleum refinery spent catalyst

Bioleaching is one of the well-known methods of metal recovery with Environmental benefits. This process has been extensively used for combating improper waste management issues along with metal reclamation. The aim of this study is to bioleach spent petroleum refinery catalyst at variant pulp densities (PD) (5, 10 and 15%) using microorganisms in acidic pH (1.5-1.6) and mesophilic temperature (30-35 °C). The study includes leaching yields of metals like nickel, molybdenum, copper and aluminum. The three bioleaching experiments with different pulp densities yielded a maximum of more than 90% nickel, 73% copper, 87% molybdenum and 24% aluminum. The results are validated 5, 10, and 15% pulp density and the result is validated with pH, Redox potential, microbial population, sulphate concentration and ferrous iron, concentration. The time saving due to faster nickel dissolution using iron and sulphur oxidizing microorganisms would be economical for the bioleaching process.

Recovery of valuable metals from spent mobile phone printed circuit boards using biochar in indirect bioleaching

Improving the bioleaching efficiency of metals from spent mobile phone printed circuit boards (PCBs) in a short time has been of major interest in recent years. In this paper, a novel cheap catalyst (oak wood biochar) was used to improve the copper and nickel bioleaching efficiency from spent mobile phone PCBs. The biochar was derived from oak wood through slow pyrolysis at a low temperature of 500 °C for 1h. The results of RSM optimization indicated that the optimum conditions to maximize copper and nickel recovery were 1.6 g/L biochar and 16 g/L pulp density. The findings indicated that compared to without the presence of biochar, the leach yields of copper and nickel were high. As much as 98% of copper and 82% of nickel were leached by indirect bioleaching under optimum conditions. The better performance in the presence of biochar is due to both galvanic interactions between biochar and solid waste. The biochemical characterization of bioleaching solution suggested that the high concentration of biochar (> 1.6 g/L) led to copper absorption by functional groups on the surface of biochar. Compared to chemical leaching, the bioleaching has better performance. Under optimum conditions, the copper and nickel recovery by indirect bioleaching was 36% and 64% more than that by chemical leaching. Also, it is found that biochar has a positive effect on the chemical leaching process. Therefore, in this paper, the function of biochar was elaborated not only in bio-hydrometallurgy but also in the hydrometallurgy process.

Fungal bioleaching of metals from refinery spent catalysts: A critical review of current research, challenges, and future directions

Petroleum refining operations such as hydroprocessing and fluid catalytic cracking (FCC) generate huge quantities of spent catalysts containing toxic and valuable metals (Ni, V, Mo, Co, W, Al, etc.), the management of which is a serious environmental issue. Besides environmental concerns, the different metals present in the spent catalysts are also a valuable commodity to modern industries. Therefore, these spent catalysts also provide an opportunity to use it as a source of value to the refiners. In recent years, a biotechnological based leaching process 'bioleaching' has emerged as a promising eco-friendly technique for the extraction of metals from these refinery spent catalysts. Among various bioleaching agents such as archean, bacterial, or fungi, the process mediated by the fungi (Aspergillus niger, Penicillium simplicissimum, and many others) is gaining attention owing to the high metal extraction ability of the various fungal produced metabolites (organic acids) under moderately acidic conditions. Furthermore, the ability of these fungi to withstand wide process conditions (pH, spent catalyst concentration, substrate types, etc.), high metal toxicity and use of low-cost organic substrate make them an ideal candidate for bioleaching. In this review article, we shed light on the role and mechanisms of fungi involved in extracting different metals from spent hydroprocessing and FCC catalysts. Key process parameters that affect the efficiency of fungal based bioleaching are discussed. The techno-economic challenges associated with the process are elaborated, and the needed future research directions to promote its commercial applications are highlighted. Based on our analysis, it can be argued that the fungi bioleaching has potential, however, some challenges (slower kinetics, and health and safety) should be addressed before the process can be scaled up for the commercial application.

Hazardous minerals mining: Challenges and solutions

Minerals are valuable resources gifted to man from the Mother Earth and quite often they need to be dug out from deep down with much effort to utilize them in many of our anthropogenic activities. The fascinating nature, colours as well as the physicochemical properties of minerals has extended their prospective value in the synthesis of various household and industrial products. However, knowledge of the mostly explored minerals, associated products, and their hazardous nature becomes relevant to its prevalence in our daily life. The harmful effects of some minerals are mostly evident from its site of occurrence, process of mining, post mining wastes left over and even in finished products. The current review focuses to evaluate the hazardous nature of minerals, cautions associated with its mining, drastic effects on human health, and ecosystem as an eye-opener to us. Finally, the effective remedies that could be implemented in the exploration of minerals are also discussed to the best of our knowledge. Bioleaching methods of rare earth elements and copper have been discussed briefly to explain the pros and cons of biological methods over conventional chemical leaching methods.

Tolerance of three fungal species to lithium and cobalt: Implications for bioleaching of spent rechargeable Li-ion batteries

AIMS

This paper aims to quantify the growth and organic acid production of Aspergillus niger, Penicillium chrysogenum and Penicillium simplicissimum when these fungi are exposed to varying levels of lithium (Li) and cobalt (Co). The study also tests whether pre-exposing the fungi to these metals enables the fungi to develop tolerance to Li or Co.

METHODS AND RESULTS

When cultures of A. niger, P. chrysogenum or P. simplicissimum were exposed to 250 mg l^-1 of Li or Co, biomass production and excretion of organic acids were significantly inhibited after 5 days of growth compared to cultures grown in the absence of these metals. Pre-exposing cultures of A. niger to 250 mg l^-1 of Li or Co for 20 days significantly increased biomass production when the fungus was subsequently sub-cultured into 250 or 500 mg l^-1 of Li or Co. However, pre-exposure of P. chrysogenum or P. simplicissimum to 250 mg l^-1 of Li or Co for 20 days did not increase biomass production.

CONCLUSIONS

Aspergillus niger, but not the Penicillium species, developed tolerance to Li and to Co during the 20-day pre-exposure period. Therefore, processes that utilize fungal bioleaching with A. niger to mobilize and recover valuable metals such as Li or Co should consider a pre-exposure step for fungi to improve their tolerance to metal toxicity.

SIGNIFICANCE AND IMPACT OF THE STUDY

Fungi may have the ability to extract valuable metals such as Li and Co from spent rechargeable batteries. However, the toxicity of the extracted metals can inhibit fungal growth and organic acid production. Pre-exposure to metals may alleviate toxicity for some fungal species. This knowledge can be used to improve the design of bioleaching protocols, increasing the potential for fungal bioleaching to become an economical and environmentally friendly method of recovering Li and Co from spent batteries.

Acidithiobacillus thiooxidans DSM 26636: An Alternative for the Bioleaching of Metallic Burrs

Metallic wastes from the metal-mechanic industry represent a serious environmental problem. The possible strategies to reduce the metal content of these industrial wastes is their biotreatment by means of sulfur-oxidizing bacteria, such as Acidithioobacillus thiooxidans DSM 26636, which has been reported as an excellent metal-leaching microorganism by its capability to oxide sublimed sulfur and produce sulfuric acid in the presence of metallic burrs, and leach metals. The metallic composition of burrs was determined by ICP-OES before and after its exposure to biological treatment. The bioleaching process was kept for 21 days at 30 °C at an orbital shaking of 150 rev/min by using Erlenmeyer flasks of 125 mL containing 30 mL of Starkey-modified media added with 0.33 g (1% w/v) of sublimed sulfur and 0.33 g (1% w/v) of metal burrs, and 3 mL of inoculum at logarithmic phase. Results showed that A. thiooxidans was able to grow at these conditions with a maximum sulfate production of 11,028 mg/L, sulfuric acid corresponded to 0.16 M, but no statistical difference was observed for days 14 and 21. A reduction in pH was observed from 2.5 to 1.3 units. Metal bioleaching in mg/kg corresponded Fe (4658.5 ± 291), Cr (237 ± 46), Al (185 ± 12), Si (71 ± 10.3), Mo (63 ± 3.6), Mn (46 ± 3.3), V (18 ± 0.94), Mg (22.2 ± 3.7), Ni (15.8 ± 1.5), and Cu (5.7 ± 1.9). Results showed that A. thiooxidans DSM 26636 was able to grow in the presence of metal-containing wastes, and although metal removal was feasible, more studies are needed to enhance metal removal.

Recovering Secondary REE Value from Spent Oil Refinery Catalysts Using Biogenic Organic Acids

Spent catalysts produced by oil refinery industries are regarded as an important secondary source for valuable metals. In particular, spent fluid catalytic cracking (FCC) catalysts represent a potential source for rare earth elements (REEs). This study aimed to exploit the leachability of spent FCC catalysts as a secondary source for La, by using an alternative organic acid lixiviant produced under optimized fungal fermentation conditions. The first chemical leaching tests revealed that citric acid (>100 mM) is a comparable alternative lixiviant to conventional inorganic acids (1 M) and that the La dissolution behavior changed significantly with different types of organic acids. The initial fungal fermentation conditions (e.g., inoculum level, substrate concentration, pH) largely affected the resultant biogenic acid composition, and its manipulation was possible in order to almost solely ferment citric acid (~130 mM) while controlling the production of unwanted oxalic acid. The performance of actual biogenic acids (direct use of cell-free spent media) and artificially reconstituted biogenic acids (a mixture of chemical reagents) was nearly identical, achieving a final La dissolution of ~74% at a pulp density of 5%. Overall, the microbiological fermentation of organic acids could become a promising approach to supply an efficient and environmentally benign alternative lixiviant for REE scavenging from spent FCC catalyst wastes.

Microorganisms and Plants in the Recovery of Metals from the Printed Circuit Boards of Computers and Cell Phones: A Mini Review

Most electrical and electronic equipment contain a printed circuit board (PCB), which is the board on which microelectronic components are mounted. The PCBs of obsolete and discarded electrical and electronic equipment are a material of great value due to their high metal content that is of commercial importance (i.e., Au, Ag, Pd, Pt, Ir, Ti, Ge, Si, Al, Cu, Ni, Zn, Fe, Sn, As, and Pb). Hydrometallurgical and pyrometallurgical methods have been used to extract metals from PCBs; however, these methods have energy and environmental disadvantages, which is why in recent years sustainable alternatives have been sought. Among these alternatives are the biological methods that contemplate the use of microorganisms and plants to recover metals from PCBs. In this review, only studies specifying the use of bacteria, fungi, and plants in the recovery of metals from the PCBs of computers and cell phones were considered, since the metallic composition of these plates varies according to the electronic equipment. In addition, the challenges and recommendations for these biotechnological processes to be improved and implemented at the industrial level in the coming years are discussed.

Enfoques microbiológicos para el tratamiento de catalizadores agotados

Los catalizadores, homogéneos o heterogéneos, son ampliamente utilizados para una gran variedad de procesos industriales, con el fin de producir combustibles limpios y muchos otros productos valiosos, siendo los catalizadores agotados provenientes del hidroprocesamiento los mayores residuos sólidos de la industria de la refinería y la contribución principal a la generación de catalizadores agotados. Debido a su naturaleza peligrosa, el tratamiento y la recuperación de metales de este tipo de residuos han ganado cada vez más importancia, debido al agotamiento de los recursos naturales y a la contaminación ambiental. Aunque ya existen técnicas disponibles para estos fines, éstas generan grandes volúmenes de desechos potencialmente peligrosos y producen emisiones de gases nocivos. Por lo tanto, las técnicas biotecnológicas pueden representar una alternativa promisoria para el biotratamiento y la recuperación de metales contenidos en los catalizadores agotados. Con este fin, se han analizado diversos microorganismos, que comprenden bacterias, arqueobacterias y hongos, capacitados para facilitar la eliminación de losmetales contenidos en estoscatalizadores. En estarevisión se presenta un amplio escenario sobre los avances con respecto al manejo de los catalizadores agotados y su tratamiento tradicional, seguido de una descripción detallada sobre los enfoques microbiológicos reportados hasta la actualidad.

Evaluation of molybdenum recovery from sulfur removed spent catalyst using leaching and solvent extraction

In this article a new spent catalyst sample preparation method was implemented for the purpose of molybdenum leaching in a single step. Further molybdenum and vanadium in the leach liquor were separated and their concentrations were enriched using the solvent extraction and stripping techniques. The impervious sulfur (S⁰) layer of the spent catalyst sample was removed using carbon disulfide (CS₂). The advantages of S⁰removal were evaluated by conducting different sets of the Mo leaching experiments and they were further examined by varying different conditions such as three lixiviants, hydrogen peroxide (H₂O₂) addition, and three leaching parameters. The leaching rate increased in an order, e.g. acetone washed < acetone-CS₂ washed < acetone washed-H₂O₂ < acetone-CS₂ washed-H₂O₂, for the experimental concentration range of different lixiviants with the maximum of 94.8%(w/w) Mo dissolution in a single step. Optimization of the pulp density was important as the interaction of lixiviant molecules with multiple reacting solid particles decreased the driving force of the chemical reactions. The solvent extraction followed by the stripping technique was found to be excellent as the concentration of vanadium and molybdenum enriched from 0.55 to 1.9 M and 0.0448 to 1.08 M, respectively.

Bioleaching of Al from spent fluid catalytic cracking catalyst using Aspergillus species

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Biogenically produced organic acids (citric acid) are used for the bioleaching of spent fluid catalytic cracking catalyst.

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Aspergillus strains-A. niger, A. foetidus, and A. carbonarius, were studied with varying catalyst loading for Al bioleaching.

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The highest Al leaching efficiency of 88.43% was obtained at 0.8% (w/v) catalyst loading using A. foetidus.

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A different carbon source, molasses was also investigated for Al bioleaching.

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Highest bioleaching efficiency of 60% (in molasses) for Al was obtained at 40 g/L sugar concentration.

Bioleaching uses biodegradable organic acids, thereby making the process environmental friendly as compared to chemical leaching. In this work, bioleaching of aluminium (Al) metal from spent catalyst was investigated by using three Aspergillus strains (A. niger, A. foetidus, and A. carbonarius). Bioleaching was performed in batch culture mode at different loading densities of spent catalyst (i.e., 0.4%, 0.8% and 1.2% (w/v)). The highest Al leaching efficiency of 88.43% was obtained at 0.8% ((w/v)) catalyst loading using A. foetidus, further increase in the catalyst loading decreased the efficiency. In addition to this, molasses was used as a carbon source (low-cost) at various concentrations for bioleaching of spent catalyst and the results were found to be significant at 40 g/L sugar concertation with 60% bioleaching efficiency. Overall, this study indicates that A. foetidus have the potential for leaching of Al from spent catalysts. Therefore, present research findings suggested that, instead of using mineral acids, organic acids (biodegradable) usage for metal leaching process is highly reliable and eco-friendly as well.

Bacterial leaching of critical metal values from Polish copper metallurgical slags using Acidithiobacillus thiooxidans

Global economy faces an increasing problem of the supply risk of critical raw materials, therefore the search for secondary resources has become an urgent issue. Copper orebodies in Poland contain substantial amounts of metals deemed critical (e.g. Co, Mo, rare earth elements (REE) or V), which are not recovered during processing. The metals of interest are concentrated in metallurgical waste residues that should be classified as a secondary resource rather than as a waste. Bioleaching is a frontier technology promising for environment-friendly treatment of slags. Therefore, the objective of this work was to study the feasibility of metal (Co, Mo, REE, V) bioleaching from copper metallurgical wastes employing Acidithiobacillus thiooxidans bacterial strain as the leaching agent. The effect of particle size (fractions <0.25 mm and 0.25-0.5 mm) and pulp density (1%, 2%) was studied using three different slag samples (lead slag - LS, shaft furnace slag - SFS and granulated slag - GS). The bioleaching experiment was set up for 28 days under acidic conditions (pH t₀ = 2.5). The results revealed that the microorganisms can catalyze metal extraction from slags as compared to leaching achieved under abiotic conditions. The optimal bioleaching yield was achieved under conditions at 0.25-0.5 mm particle size and 1% pulp density, regardless of used type of slag. After 28 days, the extracted amounts of metals were: 88% Co, 40% Mo, 83% REE and 55% V from LS, 100% Co, 44% Mo, 70% REE and 70% V from SFS and 95% Co, 70% Mo, 99% REE and 93% V from GS. All examined slags showed good potential for bioleaching of valuable elements. However, optimization of initial parameters is still needed for further efficiency improvement, especially in terms of the process duration.

Environmentally friendly recovery of valuable metals from spent coin cells through two-step bioleaching using Acidithiobacillus thiooxidans

The technology for recycling the spent coin cells is pressing needed due to a large amount of generated spent coin cells. However, there is little information about the recycling technology of spent coin cells. In this work, a two-step bioleaching method for recovery of metals from spent coin cells by Acidithiobacillus thiooxidans is performed for the first time. In this regard, the growth characteristics of A. thiooxidans was investigated in pure culture and during the two-step bioleaching approach. The highest recovery of Li, Co and Mn was achieved at a pulp density of 30 g L^-1, in values of 99%, 60%, and 20%, respectively. The structural analyzes confirmed the progress of bioleaching process. In addition, the kinetics models showed that the chemical reaction was the rate-controlling step of the two-step bioleaching of spent coin cells. The comparative results between bioleaching and chemical leaching showed that Acidithiobacillus thiooxidans can enhance the leaching of metals. Toxicity characteristic leaching procedure of the spent coin cells powder demonstrated that the bioleached residue met the environmental limitations for safe disposal. In fact, bioleaching is an effective and promising route to reduce the environmental hazard of spent coin cells.

Investigation of platinum recovery from a spent refinery catalyst with a hybrid of oxalic acid produced by Aspergillus niger and mineral acids

The capability of oxalic acid produced by Aspergillus niger was investigated for bioleaching of platinum from a refinery reforming catalyst. The spent medium mode was selected for bioleaching because of its higher efficiency at favorable pH and temperature conditions. The effects of several important factors such as the pulp density, pH and temperature on platinum recovery were optimized using Box-Behnken design of response surface methodology. The results indicated that pH adjustment during the bioleaching process increases the final platinum recovery significantly. The obtained optimum conditions were 1% for the pulp density, 0.5 for the medium pH, and 70 °C for the temperature which led to 37% platinum recovery. The significance of oxalic acid as the leaching agent in platinum bioleaching was highlighted by investigating the recovery of a blank medium without oxalic acid at the optimum conditions which was just about 13%. The presented method can be utilized in an environmentally friendly process to recover platinum from industrial catalysts.

Ultrasound-assisted oil removal of γ-Al2O3-based spent hydrodesulfurization catalyst and microwave roasting recovery of metal Mo

Currently, roasting-leaching is the main treatment process of spent hydrodesulfurization (HDS) catalyst, but it will produce impurities, such as nickel molybdate and cobalt molybdate (NiMoO₄ or CoMoO₄), which is adverse to recover valuable metals. In this paper, a combined ultrasonic-microwave method was developed to remove oil and recover molybdenum (Mo) from the spent HDS catalyst. Firstly, ethanol was used to extract the surface oil of the spent MoNiCo/Al₂O₃ catalyst with ultrasonic assistance. Effects of temperature, ultrasonic time, liquid-solid ratio and ultrasonic power on the oil removal rate were investigated systematically and the process conditions were optimized using response surface methodology (RSM). The results showed that the oil removal rate was over 99% under the optimum conditions of temperature 55 °C, ultrasonic time 2 h, liquid to solid ratio 5:1, and ultrasonic power 600 W. After oil removal, the sample was roasted in microwave field at 500 °C for 15 min. The generation of toxic gas could be effectively avoided and no hardest-to-recycle impurity CoMoO₄ was found. At last, the roasted sample was subjected to ultrasonic leaching with sodium carbonate (Na₂CO₃) solution for recovering Mo. Extraction of Mo of the deoiled sample after microwave roasting reached 94.3%, which is about 7% higher than that of oily sample. Moreover, microwave roasting method resulted in a much higher Mo extraction than traditional method for both the oily and deoiled spent catalyst. It was concluded that the ultrasonic-microwave assisted method could remarkably improve the recovery of Mo and greatly shorten the processing time.

Electrochemical effect on bioleaching of arsenic and manganese from tungsten mine wastes using Acidithiobacillus spp

Mine wastes from tungsten mine which contain a high concentration of arsenic (As) may expose many environmental problems because As is very toxic. This study aimed to evaluate bioleaching efficiency of As and manganese (Mn) from tungsten mine wastes using the pure and mixed culture of Acidithiobacillus ferrooxidans and A. thiooxidans. The electrochemical effect of the electrode through externally applied voltage on bacterial growth and bioleaching efficiency was also clarified. The obtained results indicated that both the highest As extraction efficiency (96.7%) and the highest Mn extraction efficiency (100%) were obtained in the mixed culture. A. ferrooxidans played a more important role than A. thiooxidans in the extraction of As whereas A. thiooxidans was more significant than A. ferrooxidans in the extraction of Mn. Unexpectedly, the external voltage applied to the bioleaching did not enhance metal extraction rate but inhibited bacterial growth, resulting in a reverse effect on bioleaching efficiency. This could be due to the low electrical tolerance of bioleaching bacteria. However, this study asserted that As and Mn could be successfully removed from tungsten mine waste by the normal bioleaching using the mixed culture of A. ferrooxidans and A. thiooxidans.

Biosurfactant-facilitated leaching of metals from spent hydrodesulphurization catalyst

AIMS

To investigate the capabilities of different types of biosurfactants (rhamnolipids, lipopeptides, sophorolipids) to remove metals and carbon from the hazardous spent hydrodesulphurization (HDS) catalyst generated by petroleum refineries.

METHODS AND RESULTS

Biosurfactants were prepared and used to treat spent HDS catalyst. Metal and carbon contents were analysed and compared with those from no-biosurfactant control treatments. All biosurfactant treatments increased carbon loss percentage from the spent HDS catalyst. The lipopeptide treatment LI, containing 17·34 mg ml^-1 of crude biosurfactants, caused the highest carbon loss percentage (44·5%). Rhamnolipids were, in general, better than sophorolipids and lipopeptides as metal-removing agents. The metal content decreased as the concentration of rhamnolipids decreased. The R5 treatment, which contained 0·4 mg l^-1 of crude rhamnolipids, caused the highest reduction in metal content. Molybdenum, nickle and vanadium contents were reduced by 90, 30 and 70% respectively.

CONCLUSIONS

Biosurfactants might have potential application for metals and coke removal from spent HDS catalysts. The bioleaching capability depends on the type and concentration of the biosurfactant.

SIGNIFICANCE AND IMPACT OF THE STUDY

This study, after further in-depth investigations, might lead to the development of an eco-friendly and economic technology to treat or even regenerate the environmentally hazardous spent HDS catalysts, which are generated in huge amounts by the petroleum refineries.

Chemical and petrochemical industry

The potential sources of various metals in chemical and petrochemical processes are discussed. Special emphasis is put on the catalysts used in the industry. Their main applications, compositions, especially metal contents are presented both for fresh and spent ones. The focus is on the main types of metals used in catalysts: the platinum-group metals, the rare-earth elements, and the variety of transition metals. The analysis suggested that chemical and petrochemical sectors can be considered as the secondary source of metals. Because the utilization of spent refinery catalysts for metal recovery is potentially viable, different methods were applied. The conventional approaches used in metal reclamation as hydrometallurgy and pyrometallurgy, as well as new methods include bioleaching, were described. Some industrial solutions for metal recovery from spent solution were also presented.

Changes in the fractionation profile of Al, Ni, and Mo during bioleaching of spent hydroprocessing catalysts with Acidithiobacillus ferrooxidans

Spent hydroprocessing catalysts are known to contain a variety of potentially toxic metals and therefore studies on the bioavailability and mobility of these metals are critical for understanding the possible environmental risks of the spent catalysts. This study evaluates the different chemical fractions/forms of aluminium (Al), nickel (Ni), and molybdenum (Mo) in spent hydroprocessing catalyst and the changes they undergo during bioleaching with Acidithiobacillus ferrooxidans. In the spent catalyst (prior to bioleaching), Al was primarily present in its residual form, suggesting its low environmental mobility. However, Ni comprised mainly an exchangeable fraction, indicating its high environmental mobility. Molybdenum was mainly in the oxidizable form (47.1%), which indicated that highly oxidizing conditions were required to liberate it from the spent catalyst. During bioleaching the exchangeable, reducible and oxidizable fractions of all the metals were leached, whereas the residual fractions remained largely unaffected. At the end of bioleaching process, the metals remaining in the bioleached sample were predominantly in the residual fraction (98.3-99.5%). The 'risk assessment code' (RAC) and I_R analysis also demonstrated that the environmental risks of the bioleached residue were significantly lower compared to the untreated spent catalyst. The results of this study suggest that bioleaching is an effective method in removing the metals from spent catalysts and the bioleached residue poses little environmental risk.