Recovery of metals from waste lithium ion battery leachates using biogenic hydrogen sulfide

Lithium ion battery (LIB) waste is increasing globally and contains an abundance of valuable metals that can be recovered for re-use. This study aimed to evaluate the recovery of metals from LIB waste leachate using hydrogen sulfide generated by a consortium of sulfate-reducing bacteria (SRB) in a lactate-fed fluidised bed reactor (FBR). The microbial community analysis showed Desulfovibrio as the most abundant genus in a dynamic and diverse bioreactor consortium. During periods of biogenic hydrogen sulfide production, the average dissolved sulfide concentration was 507 mg L−1 and the average volumetric sulfate reduction rate was 278 mg L−1 d−1. Over 99% precipitation efficiency was achieved for Al, Ni, Co, and Cu using biogenic sulfide and NaOH, accounting for 96% of the metal value contained in the LIB waste leachate. The purity indices of the precipitates were highest for Co, being above 0.7 for the precipitate at pH 10. However, the process was not selective for individual metals due to simultaneous precipitation and the complexity of the metal content of the LIB waste. Overall, the process facilitated the production of high value mixed metal precipitates, which could be purified further or used as feedstock for other processes, such as the production of steel

Recent progress in biohydrometallurgy and microbial characterisation

Since the discovery of microbiological metal dissolution, numerous biohydrometallurgical approaches have been developed to use microbially assisted aqueous extractive metallurgy for the recovery of metals from ores, concentrates, and recycled or residual materials. Biohydrometallurgy has helped to alleviate the challenges related to continually declining ore grades by transforming uneconomic ore resources to reserves. Engineering techniques used for biohydrometallurgy span from above ground reactor, vat, pond, heap and dump leaching to underground in situ leaching. Traditionally biohydrometallurgy has been applied to the bioleaching of base metals and uranium from sulfides and biooxidation of sulfidic refractory gold ores and concentrates before cyanidation. More recently the interest in using bioleaching for oxide ore and waste processing, as well as extracting other commodities such as rare earth elements has been growing. Bioprospecting, adaptation, engineering and storing of microorganisms has increased the availability of suitable biocatalysts for biohydrometallurgical applications. Moreover, the advancement of microbial characterisation methods has increased the understanding of microbial communities and their capabilities in the processes. This paper reviews recent progress in biohydrometallurgy and microbial characterisatio

E-waste recycling and resource recovery: A review on technologies, barriers and enablers with a focus on Oceania

Electronic e-waste (e-waste) is a growing problem worldwide. In 2019, total global production reached 53.6 million tons, and is estimated to increase to 74.7 million tons by 2030. This rapid increase is largely fuelled by higher consumption rates of electrical and electronic goods, shorter life cycles and fewer repair options. E-waste is classed as a hazardous substance, and if not collected and recycled properly, can have adverse environmental impacts. The recoverable material in e-waste represents significant economic value, with the total value of e-waste generated in 2019 estimated to be US $57 billion. Despite the inherent value of this waste, only 17.4% of e-waste was recycled globally in 2019, which highlights the need to establish proper recycling processes at a regional level. This review provides an overview of global e-waste production and current technologies for recycling e-waste and recovery of valuable material such as glass, plastic and metals. The paper also discusses the barriers and enablers influencing e-waste recycling with a specific focus on Oceania

A comparison of methods for the characterisation of waste-printed circuit boards

Electronic waste is a growing waste stream globally. With 54.6 million tons generated in 2019 worldwide and with an estimated value of USD 57 billion, it is often referred to as an urban mine. Printed circuit boards (PCBs) are a major component of electronic waste and are increasingly considered as a secondary resource for value recovery due to their high precious and base metals content. PCBs are highly heterogeneous and can vary significantly in composition depending on the original function. Currently, there are no standard methods for the characterisation of PCBs that could provide information relevant to value recovery operations. In this study, two pre-treatments, smelting and ashing of PCB samples, were investigated to determine the effect on PCB characterisation. In addition, to determine the effect of particle size and element-specific effects on the characterisation of PCBs, samples were processed using four different analytical methods. These included multi-acid digestion followed by inductively coupled plasma optical emission spectrometry (ICP-OES) analysis, nitric acid digestion followed by X-ray fluorescence (XRF) analysis, multi-acid digestion followed by fusion digestion and analysis using ICP-OES, and microwave-assisted multi-acid digestion followed by ICP-OES analysis. In addition, a mixed-metal standard was created to serve as a reference material to determine the accuracy of the various analytical methods. Smelting and ashing were examined as potential pre-treatments before analytical characterisation. Smelting was found to reduce the accuracy of further analysis due to the volatilisation of some metal species at high temperatures. Ashing was found to be a viable pre-treatment. Of the four analytical methods, microwave-assisted multi-acid digestion offered the most precision and accuracy. It was found that the selection of analytical methods can significantly affect the accuracy of the observed metal content of PCBs, highlighting the need for a standardised method and the use of certified reference material

Effect of initial cell concentration on Bio-Oxidation of pyrite before gold cyanidation

Bio-oxidation of refractory sulfidic gold minerals has been applied at the commercial scale as a pre-treatment to improve gold yields and reduce chemical consumption during gold cyanidation. In this study, the effect of initial cell concentration on the oxidation of pyritic gold ore was evaluated with four aerated bioreactors at 30 °C with 10% pulp density and pH maintained at 1.4 with NaOH. Results of NaOH consumption and changes in soluble Fe and S concentrations indicated that increasing the initial cell concentration from 2.3 × 107 to 2.3 × 1010 cells mL−1 enhanced pyrite oxidation during the first week. However, by day 18 the reactor with the lowest initial cell concentration showed profound performance enhancement based on soluble Fe and S concentrations, sulfide-S and pyrite contents in the residues, and subsequent gold leaching of the bio-oxidation residues by cyanidation. Overall, the results showed that the cell concentration was clearly beneficial during the initial stages of oxidation (first 7–8 days)

Multistage leaching of metals from spent lithium ion battery waste using electrochemically generated acidic lixiviant

Lithium ion battery (LIB) waste contains significant valuable resources that could be recovered and reused to manufacture new products. This study aimed to develop an alternative process for extracting metals from LIB waste using acidic solutions generated by electrolysis for leaching. Results showed that solutions generated by electrolysis of 0.5 M NaCl at 8 V with graphite or mixed metal oxide (MMO) electrodes were weakly acidic and leach yields obtained under single stage (batch) leaching were poor (<10%). This was due to the highly acid-consuming nature of the battery waste. Multistage leaching with the graphite electrolyte solution improved leach yields overall, but the electrodes corroded over time. Though yields obtained with both electrolyte leach solutions were low when compared to the 4 M HCl control, there still remains potential to optimise the conditions for the generation of the acidic anolyte solution and the solubilisation of valuable metals from the LIB waste. A preliminary value proposition indicated that the process has the potential to be economically feasible if leach yields can be improved, especially based on the value of recoverable cobalt and lithium

Increasing cell concentration does not affect specific ferrous iron oxidation rate in a continuously stirred tank bioreactor

Microbial oxidation of ferrous to ferric iron allows efficient oxidative processing of sulfide minerals under ambient conditions. This study determined the effect of cell concentration of a mixed mesophilic microbial culture on iron oxidation rate, and evaluated if there was a cell concentration threshold that dictates a maximal volumetric iron oxidation rate. A bioreactor with feedback-loading of ferrous media was operated at 30 °C to maintain a redox potential of +480 mV vs. Ag/AgCl at pH of 1.3. A positive and linear correlation (R = 0.955) between the cell concentration (6.8 × 107–7.1 × 109 cells mL−1) and volumetric biological iron oxidation (up to 6.9 g L−1 h−1) was observed. The specific iron oxidation was not affected by cell concentration, and no biocatalytic threshold was observed. This indicated that a high cell concentration can be used to achieve a high volumetric iron oxidation rate, enabling the use of a compact reactor size

Recent advances in biomining and microbial characterisation

Since the discovery of bioleaching microorganisms and their role in metal extraction in the 1940s, a number of technical approaches have been developed to enhance microbially catalysed solubilisation of metals from ores, concentrates and waste materials. Biomining has enabled the transformation of uneconomic resources to reserves, and thus help to alleviate the challenges related to continually declining ore grades. The rapid advancement of microbial characterisation methods has vastly increased our understanding of microbial communities in biomining processes. The objective of this paper is to review the recent advances in biomining processes and microbial characterisation

Potential of metals leaching from printed circuit boards with biological and chemical lixiviants

The generation of electronic waste (e-waste) is an issue with global consequences and therefore the proper management and recycling of e-waste are of increasing importance. Printed circuit boards (PCBs), which are a common component of e-waste, have a high valuable metal content which also makes this material an important secondary resource. In this study, biohydrometallurgical extraction of metals from PCBs was investigated as a potential alternative to conventional hydrometallurgical or pyrometallurgical processing options. An indirect non-contact leaching approach using ferric iron generated by Acidithiobacillus ferrooxidans was compared to chemical ferric sulfate leaching of Cu, Ni, Zn and Al from milled high-grade PCBs at 1% pulp density at Fe3+ concentrations of 5–20 g L−1 and at a pH range of 0.6–1.2. The roles of redoxolysis and acidolysis were examined by comparing ferric leaching with sulfuric acid leaching conducted at initial pH values of 0.8–1.4. Results showed that the supplementation of ferric iron significantly (p < 0.05) improved the chemical leaching yields as compared to sulfuric acid leaching for Cu (47.4% to 66.3%), Al (55.3% to 100%), Zn (45.5% to 92.4%) and Ni (61.0% to 97.7%) at pH 0.8. Increase in ferric iron concentration and decrease in pH also significantly (p < 0.05) improved the yield for both biological and chemical leaching. The optimal condition for overall metal bioleaching was at 20 g L−1 ferric iron at an initial pH of 0.6, yielding 87% for Cu and 100% for Al, Zn and Ni. Since no significant variation was found between chemical ferric sulfate and biogenic ferric sulfate leaching at a majority of the tested ferric concentrations, this study suggested that using biogenic lixiviants for extracting metals from PCBs is a viable alternative to chemical leaching

Prospective directions for biohydrometallurgy

Biohydrometallurgy has been commercially applied for the extraction of base metals from low-grade sulfidic ores and the pre-treatment of refractory sulfidic gold-containing minerals. Recent research explores its potential for other types of commodities, such as rare earth elements, and ores found in deep subsurface of the Earth, ocean floor and outer space. The application of biohydrometallurgy for extracting resources from waste streams is also gaining increasing interest to support the move towards a circular economy. The utilisation of complex feedstock is associated with new challenges, which may require the integration of various unit processes that combine biological approaches and/or electrochemistry, with physical or chemical processing. New biolixiviants are also being explored to mitigate harmful environmental impacts. The range of biocatalysts available for biohydrometallurgy can be increased through bioprospecting of novel biomining microbes, increasing the metabolic capability of microbes through adaptive evolution and engineering microbes through synthetic biology. New modelling and artificial intelligence tools are also expanding the opportunities for optimising biotechnical processes. This paper reviews recent trends and prospective directions for biohydrometallurgy