Techno-economic feasibility of a recycling plant for the extraction of metals and boehmite from hazardous petroleum spent catalysts.

Petroleum spent hydroprocessing catalysts are hazardous solid waste, the efficient recycling of which is a serious challenge to refineries. However, information on the economic feasibility of spent catalysts recycling plants is scarce, which is critical for environmental authorities and decision-makers. In this work, an innovative recycling scheme targeting hydrometallurgical recovery of base metals (Ni, Mo, and V) and transforming low-value Al residue into a high-value boehmite (γ-AlOOH) as the key product was considered an efficient way to beneficiate the hazardous spent hydroprocessing catalysts.

Metal leaching from refinery waste hydroprocessing catalyst.

The present study aims to develop an eco-friendly methodology for the recovery of nickel (Ni), molybdenum (Mo), and vanadium (V) from the refinery waste spent hydroprocessing catalyst. The proposed process has two stages: the first stage is to separate alumina, while the second stage involves the separation of metal compounds. The effectiveness of leaching agents, such as NHOH, (NH)CO, and (NH)SO, for the extraction of Mo, V, Ni, and Al from the refinery spent catalyst has been reported as a function of reagent concentration (0.

A preliminary process design and economic assessment of a catalyst rejuvenation process for waste disposal of refinery spent catalysts.

Spent hydroprocessing catalysts from refineries have been classified as hazardous solid waste by the United States Environmental Protection Agency (USEPA), refiners must find a viable but economical solution to solve this serious environmental issue. Catalyst rejuvenation is an attractive option for minimizing the environmental problems associated with spent catalysts. In this study, a preliminary design for such a process and the corresponding economic analysis are performed to assess the proposed catalyst rejuvenation process for metal-fouled spent catalysts generated in residue hydroprocessing units.