Screening and optimization of effective parameters in biological extraction of heavy metals from refinery spent catalysts using a thermophilic bacterium

A comprehensive review of bioleaching optimization by statistical approaches: recycling mechanisms, factors affecting, challenges, and sustainability

A serious environmental problem is associated with the accumulation of solid waste on the Earth. Researchers are encouraged to find an efficient and sustainable method to recover highly profitable heavy metals and precious and base metals. Bioleaching is a green method of recovering valuable metals from solid waste. Optimizing the variables and conditions of the bioleaching process is crucial to achieving maximum metal recovery most cost-effectively. The conventional optimization method (one factor at a time) is well-studied. However, it has some drawbacks, such as the necessity of more experiments, the need to spend more time, and the inability to illuminate the synergistic effect of the variables. Optimization studies are increasingly utilizing response surface methodology (RSM) because it provides details about the interaction effects of variables with fewer experiments. This review discusses the application of RSM for bioleaching experiments from other solid wastes. It discusses the Central Composite and Box-Behnken designs as the most commonly used designs for optimizing bioleaching methods. The most influential factors for increasing the heavy metal recovery rate in applying RSM using the bioleaching process are recognized, and some suggestions are made for future research.

Current Trends in Metal Biomining with a Focus on Genomics Aspects and Attention to Arsenopyrite Leaching-A Review

The presented review is based on scientific microbiological articles and patents in the field of biomining valuable metals. The main attention is paid to publications of the last two decades, which illustrate some shifts in objects of interest and modern trends both in general and applied microbiology. The review demonstrates that microbial bioleaching continues to develop actively, despite various problems in its industrial application. The previous classic trends in the microbial bioleaching persist and remain unchanged, including (i) the search for and selection of new effective species and strains and (ii) technical optimization of the bioleaching process. Moreover, new trends were formed during the last decades with an emphasis on the phylogeny of leaching microbiota and on genomes of the leaching microorganisms. This area of genomics provides new, interesting information and forms a basis for the subsequent construction of new leaching strains. For example, this review mentions some changed strains with increased resistance to toxic compounds. Additionally, the review considers some problems of bioleaching valuable metals from toxic arsenopyrite.

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.

Bioleaching of Iron, Copper, Lead, and Zinc from the Sludge Mining Sediment at Different Particle Sizes, pH, and Pulp Density Using Acidithiobacillus ferrooxidans

Globally, the amounts of metal ore deposits have been declining, so the research directions investigating the extraction of metals from materials that are classified as waste are gaining more importance every year. High concentrations of Cu, Pb, Zn, and Fe were analyzed in the sludge sediment (Zlaté Hory, Czech Republic), which is a waste product of the mining industry. In the bioleaching process, bacterial cells have been established as being able to convert metals from solid to liquid phase. However, the most important parameters of bioleaching are particle size, pH, and pulp density, thus our research focused on their optimization. The acidophilic and mesophilic bacteria Acidithiobacillus ferrooxidans were applied due to the high Fe content in the sample. The recovery of metals in the leachate was determined by F-AAS and the residual metal concentrations in the waste fraction were analyzed by XRF. The grain size fractions <40 µm –200 µm were investigated. The atomic absorption spectrometry (AAS) results show that the highest Fe (76.48%), Cu (82.01%), and Pb (88.90%) recoveries were obtained at particle size of 71–100 μm. Zn was dissolved for all fractions above 90%. Experiments with different pH values were performed at a pH of 1.6–2.0. The highest dissolution rates of Zn, Fe, and Cu were achieved with a suspension pH of 1.8, where 98.73% of Zn, 85.42% of Fe, and 96.44% of Cu were recovered. Due to the high percentage dissolution of metals, experiments were performed under pilot conditions in a bioreactor at a pulp density of 2.5% and 4.2% (w/v). From an economic point of view, the leaching time of 28 days was evaluated as sufficient.

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.

An investigation of the effect of operational conditions on a sequential extraction procedure for arsenic in soil in Thailand

Sequential Extraction Procedure (SEP) can be used to evaluate the toxicity characteristics of heavy metals in soil, including arsenic (As), by separating the metals into several different fractions using selective extraction solvents in sequence. To accomplish this separation task, various factors that are known to affect the extraction process should be carefully considered. This research aimed to investigate the effect of the operational conditions on the SEP for As in soil using experimental designs. In the first step, a Plackett-Burman design was used twice to screen the important extraction variables from a total of 19 studied variables. As a result, SSR, extraction time of the first fraction (F1), and concentrations of sodium acetate (NaOAc) in F2 and ammonium oxalate (NH₄Ox) in F6 were identified as significant to the amount of the extracted As. The selected variables were further investigated using a central composite design with response surface methodology. The optimized SEP characterized by 1:75 g:mL of SSR, an extraction time of 7 h 20 min of F1, 0.16 M of NaOAc and 0.11 M of NH₄OAc were applied to extract a sample from contaminated agricultural soil obtained from the north of Thailand. The fractionation result was compared with the result obtained from a previously reported SEP method. It was found that similar extraction results could be achieved (91-97% As recovery). However, the optimized method revealed certain advantages in that it required dramatically less operation time (from 68 h to 32 h) and lower concentrations of the extraction solvents.

Effects of sulfur dosage and inoculum size on pilot-scale thermophilic bioleaching of heavy metals from sewage sludge

Land application of sewage sludge has received significant attention in recent years but the presence of elevated heavy metals in the sludge limits its land application. The purposes of this study were to investigate the effects of sulfur dosage and inoculum size on the thermophilic bioleaching of heavy metals from sewage sludge in a pilot-scale bioreactor. The microbial communities in this thermophilic bioleaching process were also identified using real-time polymerase chain reaction (real-time PCR). The results showed that the oxidation of sulfur and metal solubilization decreased with the increasing sulfur dosage. When the sulfur dosage was greater than 2% (w/v), the sulfur oxidation and metal solubilization rates decreased, indicating that the thermophilic bioleaching was hindered by high levels of substrate. However, it was found that the efficiency of metal solubilization and solid degradation was increased with the increase of inoculum size in the range from 5% to 20%. At the end of bioleaching, the efficiency of Mn, Zn, Ni, Cu and Cr from the sewage sludge reached 73-100%, 51-60%, 38-52%, 17-43% and 1-38%, respectively, while SS and VSS were degraded by 33-48% and 47-67%, respectively. Based on the analysis of real-time PCR, Sulfobacillus acidophilus was observed to be the predominant species (13-67% of total bacteria), whereas the populations of Sulfobacillus thermosulfidooxidans and Acidithiobacillus caldus were accounted relatively low (<1%).

Column bioleaching of metals from refinery spent catalyst by Acidithiobacillus thiooxidans: Effect of operational modifications on metal extraction, metal precipitation, and bacterial attachment

The feasibility of column bioleaching in the recovery of valuable metals (Ni, V, Mo, and Al) from an uncrushed petroleum refinery spent hydroprocessing catalyst using Acidithiobacillus thiooxidans has been reported. Different operational strategies such as submerged bioleaching in continuous mode, submerged bioleaching in resting period mode, free flow bioleaching in continuous mode, and free flow bioleaching in resting period mode were tested to find out the optimum bioleaching strategy for the recovery of metals from spent hydroprocessing catalyst. Among various operational modifications, submerged bioleaching in continuous mode was considered as the best strategy in which about 82.9% of Ni, 33.4% of Al, and 22.7% of Mo were leached after 315 h of column operation. The maximum yield of V (53.6%) in this column was achieved in 105 h, after which, a rapid decrease in its yield was observed, possibly due to its precipitation. The field emission scanning electron microscopy (FESEM) analysis revealed the presence of V in precipitates. The modified kinetic models showed that the leaching of Al, V and Mo followed the chemical control model, whereas the dissolution of Ni was controlled by diffusion control reaction. The bacterial attachment study with FESEM indicated that the metal toxicity was induced on bacterial cells attached to the sulfur particles. The results of the current study indicate that column bioleaching of spent hydroprocessing catalyst is effective in leaching of Ni and V, whereas leaching of Al and Mo require further treatments.

Metal biorecovery and bioremediation: Whether or not thermophilic are better than mesophilic microorganisms

Metal mobilization and immobilization catalyzed by microbial action are key processes in environmental biotechnology. Metal mobilization from ores, mining wastes, or solid residues can be used for recovering metals and/or remediating polluted environments; furthermore, immobilization reduces the migration of metals; cleans up effluents plus ground- and surface water; and, moreover, can help to concentrate and recover metals. Usually these processes provide certain advantages over traditional technologies such as more efficient economical and environmentally sustainable results. Since elevated temperatures typically increase chemical kinetics, it could be expected that bioprocesses should also be enhanced by replacing mesophiles with thermophiles or hyperthermophiles. Nevertheless, other issues like process stability, flexibility, and thermophile-versus-mesophile resistance to acidity and/or metal toxicity should be carefully considered. This review critically analyzes and compares thermophilic and mesophilic microbial performances in recent and selected representative examples of metal bioremediation and biorecovery.

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.

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.

Integrated bioleaching of copper metal from waste printed circuit board-a comprehensive review of approaches and challenges

Waste electrical and electronic equipment (e-waste) is the most rapidly growing waste stream in the world, and the majority of the residues are openly disposed of in developing countries. Waste printed circuit boards (WPCBs) make up the major portion of e-waste, and their informal recycling can cause environmental pollution and health risks. Furthermore, the conventional disposal and recycling techniques-mechanical treatments used to recover valuable metals, including copper-are not sustainable in the long term. Chemical leaching is rapid and efficient but causes secondary pollution. Bioleaching is a promising approach, eco-friendly and economically feasible, but it is slower process. This review considers the recycling potential of microbes and suggests an integrated bioleaching approach for Cu extraction and recovery from WPCBs. The proposed recycling system should be more effective, efficient and both technically and economically feasible.

Enhancement of simultaneous gold and copper recovery from discarded mobile phone PCBs using Bacillus megaterium: RSM based optimization of effective factors and evaluation of their interactions

Bioleaching of Au from mobile phone printed circuit boards (MPPCBs) was studied, using Bacillus megaterium which is a cyanogenic bacterium. To maximize Au extraction, initial pH, pulp density, and glycine concentration were optimized via response surface methodology (RSM). Bioleaching of Cu, an important inhibitor on Au recovery, was also examined. To maximize Au recovery, the optimal condition suggested by the models was initial pH of 10, pulp density of 8.13g/l, and glycine concentration of 10g/l. Under the optimal condition, approximately 72% of Cu and 65g Au/ton MPPCBs, which is 7 times greater than the recovery from gold mines, was extracted. Cu elimination from the MPPCBs having a rich content of Au did not cause a significant effect on Au recovery. It was found that when the ratio of Cu to Au is high, Cu elimination can considerably improve Au recovery. B. megaterium could extract the total Au from PCBs containing 130g Au/ton MPPCBs.

Maximization of organic acids production by Aspergillus niger in a bubble column bioreactor for V and Ni recovery enhancement from power plant residual ash in spent-medium bioleaching experiments

Spent-medium bioleaching of V and Ni from a power plant residual ash (PPR ash) was conducted using organic acids produced by Aspergillus niger. The production of organic acids in a bubble column bioreactor was optimized through selecting three most influencing factors. Under optimum condition of aeration rate of 762.5(ml/min), sucrose concentration of 101.9(g/l) and inoculum size of 40(ml/l), respectively 17,185, 4539, 1042 and 502(ppm) of oxalic, gluconic, citric and malic acids were produced. Leaching experiments were carried out using biogenic produced organic acids under leaching environment temperature of 60°C and rotary shaking speed of 135rpm, with various pulp densities of 1, 2, 3, 5, 7 and 9(%w/v). The results showed that biogenic produced organic acids leached V much more efficiently than Ni so that even at high pulp density of 9(%w/v), 83% of V was recovered while Ni recovery yield was 30%.

Relationship between microbial community dynamics and process performance during thermophilic sludge bioleaching

Heavy metals can be removed from the sludge using bioleaching technologies at thermophilic condition, thereby providing an option for biotreatment of wasted sludge generated from wastewater treatment. The purposes of this study were to establish a molecular biology technique, real-time PCR, for the detection and enumeration of the sulfur-oxidizing bacteria during the thermophilic sludge bioleaching. The 16S rRNA gene for real-time PCR quantification targeted the bioleaching bacteria: Sulfobacillus thermosulfidooxidans, Sulfobacillus acidophilus, and Acidithiobacillus caldus. The specificity and stringency for thermophilic sulfur-oxidizing bacteria were tested before the experiments of monitoring the bacterial community, bacterial number during the thermophilic sludge bioleaching and the future application on testing various environmental samples. The results showed that S. acidophilus was identified as the dominant sulfur-oxidizing bacteria, while A. caldus and S. thermosulfidooxidans occurred in relatively low numbers. The total number of the sulfur-oxidizing bacteria increased during the thermophilic bioleaching process. Meanwhile, the decrease of pH, production of sulfate, degradation of SS/VSS, and solubilization of heavy metal were found to correlate well with the population of thermophilic sulfur-oxidizing bacteria during the bioleaching process. The real-time PCR used in this study is a suitable method to monitor numbers of thermophilic sulfur-oxidizing bacteria during the bioleaching process.

Bioleaching of fuel-oil ash using Acidithiobacillus thiooxidans in shake flasks and a slurry bubble column bioreactor

This work investigated a bioleaching process to remove V, Ni and Cu from fuel-oil ash (FOA) using Acidithiobacillus thiooxidans.

Chelation technology: a promising green approach for resource management and waste minimization

Green chemical engineering recognises the concept of developing innovative environmentally benign technologies to protect human health and ecosystems. In order to explore this concept for minimizing industrial waste and for reducing the environmental impact of hazardous chemicals, new greener approaches need to be adopted for the extraction of heavy metals from industrial waste. In this review, a range of conventional processes and new green approaches employed for metal extraction are discussed in brief. Chelation technology, a modern research trend, has shown its potential to develop sustainable technology for metal extraction from various metal-contaminated sites. However, the interaction mechanism of ligands with metals and the ecotoxicological risk associated with the increased bioavailability of heavy metals due to the formation of metal-chelant complexes is still not sufficiently explicated in the literature. Therefore, a need was felt to provide a comprehensive state-of-the-art review of all aspects associated with chelation technology to promote this process as a green chemical engineering approach. This article elucidates the mechanism and thermodynamics associated with metal-ligand complexation in order to have a better understanding of the metal extraction process. The effects of various process parameters on the formation and stability of complexes have been elaborately discussed with respect to optimizing the chelation efficiency. The non-biodegradable attribute of ligands is another important aspect which is currently of concern. Therefore, biotechnological approaches and computational tools have been assessed in this review to illustrate the possibility of ligand degradation, which will help the readers to look for new environmentally safe mobilizing agents. In addition, emerging trends and opportunities in the field of chelation technology have been summarized and the diverse applicability of chelation technology in metal extraction from contaminated sites has also been reviewed.

Simultaneous recovery of Ni and Cu from computer-printed circuit boards using bioleaching: statistical evaluation and optimization

Computer printed circuit boards (CPCBs) have a rich metal content and are produced in high volume, making them an important component of electronic waste. The present study used a pure culture of Acidithiobacillus ferrooxidans to leach Cu and Ni from CPCBs waste. The adaptation phase began at 1g/l CPCBs powder with 10% inoculation and final pulp density was reached at 20g/l after about 80d. Four effective factors including initial pH, particle size, pulp density, and initial Fe(3+) concentration were optimized to achieve maximum simultaneous recovery of Cu and Ni. Their interactions were also identified using central composite design in response surface methodology. The suggested optimal conditions were initial pH 3, initial Fe(3+) 8.4g/l, pulp density 20g/l and particle size 95μm. Nearly 100% of Cu and Ni were simultaneously recovered under optimum conditions. Finally, bacterial growth characteristics versus time at optimum conditions were plotted.

Platinum and rhenium extraction from a spent refinery catalyst using Bacillus megaterium as a cyanogenic bacterium: statistical modeling and process optimization

The present study evaluated the potential of Bacillus megaterium as a cyanogenic bacterium to produce cyanide for solubilization of platinum and rhenium from a spent refinery catalyst. Response surface methodology was applied to study the effects and interaction between two main effective parameters including initial glycine concentration and pulp density. Maximum Pt and Re recovery was obtained 15.7% and 98%, respectively, under optimum conditions of 12.8 g/l initial glycine concentration and 4% (w/v) pulp density after 7 days. Increasing the free cyanide concentration to 3.6 mg/l, varying the pH from 6.7 to 9, and increasing the dissolved oxygen from 2 to 5mg/l demonstrated the growth characteristics of B. megaterium during bioleaching process. The modified shrinking core model was used to determine the rate limiting step of the process. It was found that diffusion through the product layer is the rate controlling step.

Cr and Ni recovery during bioleaching of dewatered metal-plating sludge using Acidithiobacillus ferrooxidans

This study determined the optimal conditions required to attain maximum metal recovery in the bioleaching process of dewatered metal-plating sludge using Acidithiobacillus ferrooxidans (A. ferrooxidans). Adaptation of this strain was carried up to 1% (w/v) of the sample. Three factors including initial pH, initial Fe(3+) concentration and pulp density were selected as the effective factors and were optimized using a central composite design of response surface methodology. An initial pH of 1, pulp density of 9 g/l and initial Fe(3+) concentration of 1g/l were determined to be optimum values by the statistical models. The highest extractions for Cr and Ni under optimal conditions were 55.6% and 58.2%, respectively. Bioleaching kinetics was investigated using a modified shrinking core model to better understand the mechanism of the leaching reaction. The model predictions indicate that the diffusion step controlled the overall dissolution kinetics and is the rate controlling step.

Optimization of two-step bioleaching of spent petroleum refinery catalyst by Acidithiobacillus thiooxidans using response surface methodology

A central composite design (CCD) combined with response surface methodology (RSM) was employed for maximizing bioleaching yields of metals (Al, Mo, Ni, and V) from as-received spent refinery catalyst using Acidithiobacillus thiooxidans. Three independent variables, namely initial pH, sulfur concentration, and pulp density were investigated. The pH was found to be the most influential parameter with leaching yields of metals varying inversely with pH. Analysis of variance (ANOVA) of the quadratic model indicated that the predicted values were in good agreement with experimental data. Under optimized conditions of 1.0% pulp density, 1.5% sulfur and pH 1.5, about 93% Ni, 44% Al, 34% Mo, and 94% V was leached from the spent refinery catalyst. Among all the metals, V had the highest maximum rate of leaching (Vmax) according to the Michaelis-Menten equation. The results of the study suggested that two-step bioleaching is efficient in leaching of metals from spent refinery catalyst. Moreover, the process can be conducted with as received spent refinery catalyst, thus making the process cost effective for large-scale applications.