Bioleaching of a lateritic ore (Piauí, Brazil) in percolators

Abstract

Heap leaching of laterites for extraction of nickel and cobalt is an attractive alternative to capital and energy intensive high pressure acid leaching, the dominant hydrometallurgical processing technology for limonitic laterites. Conventional approach for heap leaching of laterites is leaching with sulfuric acid. Consumption of sulfuric acid during heap leaching is substantial and industrial-scale operations require construction of a sulfuric acid production plant on site. In this study, heap bioleaching of laterites was simulated in laboratory scale column percolators and bioleaching of nickel and cobalt from lateritic material was successfully demonstrated for the first time. The process is based on biooxidation of the bacterially modified “wet sulfur” inside column percolators by sulfur-oxidizing acidophilic bacteria Acidithiobacillus thiooxidans. The “wet sulfur“ was generated in a bioreactor with the bacterial culture, harvested, and mixed with lateritic ore before forming agglomerates to be filled in the percolator columns. Liquid was circulated with a flow rate of 8 mL/min. Maximum metal extraction was 66% nickel, 95% cobalt, 10% iron, 55% magnesium and 89% manganese from the Piauí lateritic ore after one month bioleaching. For comparison, chemical leaching with 1 M sulfuric acid with or without addition of 10 g/L of ferrous sulfate heptahydrate as reductant resulted in extraction of approximately 80% nickel, 86% cobalt, 33% iron, 50% magnesium and 81% manganese. With bioleaching a higher cobalt but lower nickel and iron extraction was achieved, i.e. a better selectivity of nickel over iron extraction, as well as a relatively higher pH of the pregnant leach solution requiring less limestone and, consequently, lower CO₂ emission and generation of iron cake waste in case of laterite bioleaching. Overall, the results are promising and show potential of laterite heap bioleaching to be further developed to application on industrial scale.