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

Pyrite oxidation by mixed mesophilic acidophiles was conducted under conditions of controlled and non-controlled redox potential to investigate the role of sessile microbes in pyrite oxidation. Microbes attached on pyrite surfaces by extracellular polymeric substances (EPS), and their high coverage rate was characterized by scanning electron microscopy (SEM), confocal laser scanning microscopy (CLSM) and atomic force microscopy (AFM). The dissolution of pyrite was negligible if the redox potential was controlled below 650 mV (near the rest potential of pyrite), even though the bacteria were highly active and a high coverage rate was observed on pyrite surfaces. However, with un-controlled redox potential the rate of pyrite oxidation increased greatly with an increasing redox potential. This study demonstrates that sessile microbes play a limited role in pyrite oxidation at a redox potential below 650 mV, and highlight the importance of solution redox potential for pyrite oxidation. This has implications for acid mine drainage control and pyrite oxidation control in biometallurgy practice.

The function of microbial contact leaching to pyrite oxidation was investigated by analyzing the differences of residue morphologies, leaching rates, surface products, and microbial consortia under different conditions in this study. This was achieved by novel equipment that can control the redox potential of the solution and isolate pyrite from microbial contact oxidation. The morphology of residues showed that the corrosions were a little bit severer in the presence of attached microbes under 750 mV and 850 mV (vs. SHE). At 650 mV, the oxidation of pyrite was undetectable even in the presence of attached microbes. The pyrite dissolution rate was higher with attached microbes than that without attached microbes at 750 mV and 850 mV. The elemental sulfur on the surface of pyrite residues with sessile microorganisms was much less than that without attached microbes at 750 mV and 850 mV, showing that sessile acidophiles may accelerate pyrite leaching by reducing the elemental sulfur inhibition. Many more sulfur-oxidizers were found in the sessile microbial consortium which also supported the idea. The results suggest that the microbial “contact leaching” to pyrite oxidation is limited and relies on the elimination of elemental sulfur passivation by attached sulfur-oxidizing microbes rather than the contact oxidation by EPS-Fe.

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

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