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

In the present study, using Aspergillus niger and Penicillium tricolor, the influence of the selected parameters, including sucrose concentration, inoculation size of spores, pulp density, and pre-culture time, on the bioleaching efficiency (biomass, organic acids production, and vanadium extraction, respectively) of red mud were studied. The bioleaching kinetics under optimal conditions were also explored. Sucrose concentration showed a positive linear effect on bioleaching efficiency below 143.44 and 141.82 g/L using A. niger and P. tricolor, respectively. However, a higher concentration was unfavorable for vanadium extraction. The inoculation size of spores showed an insignificant effect on both biomass and vanadium extraction if it exceeded the lowest coded levels (0.5 × 10⁷/mL). Red mud pulp density showed a negative effect on the bioleaching efficiency of A. niger but a positive effect on organic acids production and vanadium extraction of P. tricolor. A pre-culture was indispensable for A. niger but not for P. tricolor due to the fact of its isolation from the red mud examined in this study. The kinetics analysis showed that the leaching rate of vanadium followed a two-domain behavior: initially, a rapid leaching period of approximately 10–15 days and, subsequently, a slow leaching period. Considering the change of the particles’ appearance as well as in the elemental composition of the bioleached red mud, it is speculated that the rate of leaching agents through the silicon minerals was the rate-limiting step of dissolution kinetics under the fungal bioleaching process.