An environmentally friendly process for the recovery of valuable metals from spent refinery catalysts

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. A preliminary techno-economic evaluation of such a recycling scheme was performed to assess the feasibility of the proposed recycling scheme. The recovery cost (valuable metals and boehmite) and potential revenue were estimated to study the economics of the process. The preliminary results have suggested that the recycling scheme is economically feasible with a high internal rate of return (IRR) of 12.3%, a net present value of 38.6 million USD, and a short payback period of 8.7 years. Furthermore, a sensitivity analysis (± 10%) conducted on key parameters showed that the selling prices of the finished products and the cost of chemicals were the most important factors affecting plant economics. Overall, the recycling scheme was sustainable and avoided landfilling of spent catalysts as the residue can be beneficiated into a high-value product. The results from the economic feasibility study are likely to assist the stakeholders and decision-makers in making investment and policy decisions for the valorization of spent hydroprocessing catalysts.

An environmentally friendly method for extraction of cobalt and molybdenum from spent catalysts using deep eutectic solvents (DESs)

There has been a substantially increasing demand for energy critical elements (ECEs) in recent years as energy-related technology has advanced rapidly. Spent catalysts are known as potential sources of ECCs such as Ni, Co, Mo, W, V, and rare earth elements. This study developed a novel environmentally friendly process for recovering cobalt and molybdenum from spent hydroprocessing catalysts using deep eutectic solvents (DESs). DESs based on p-toluenesulfonic acid achieved high metal extraction at 100 °C and a pulp density of 20 g/L for 48 h which 93% of cobalt and 87% of molybdenum were dissolved. FT-IR and H-NMR analyses were conducted to determine whether hydrogen bonds form between p-toluenesulfonic acid-based DES components. Leaching kinetic models were also developed for DES systems. The experimental results were well-matched with the shrinking core models. The leaching controlling step of DES-1 was determined to be the diffusion through the product layer based on kinetic studies, with an activation energy of 22.56 kJ/mol for Co and 29.34 kJ/mol for Mo in DES-1. Similarly, the mixed control reaction with an activation energy of 38.09 kJ/mol for Co and 31.48 kJ/mol for Mo in DES-2 was found to control the leaching kinetic mechanism of the DES-2 sample.

Identification of Bacillus megaterium and Microbacterium liquefaciens genes involved in metal resistance and metal removal

Bacillus megaterium MNSH1-9K-1 and Microbacterium liquefaciens MNSH2-PHGII-2, 2 nickel- and vanadium-resistant bacteria from mine tailings located in Guanajuato, Mexico, are shown to have the ability to remove 33.1% and 17.8% of Ni, respectively, and 50.8% and 14.0% of V, respectively, from spent petrochemical catalysts containing 428 ± 30 mg·kg(-1) Ni and 2165 ± 77 mg·kg(-1) V. In these strains, several Ni resistance determinants were detected by conventional PCR. The nccA (nickel-cobalt-cadmium resistance) was found for the first time in B. megaterium. In M. liquefaciens, the above gene as well as the czcD gene (cobalt-zinc-cadmium resistance) and a high-affinity nickel transporter were detected for the first time. This study characterizes the resistance of M. liquefaciens and B. megaterium to Ni through the expression of genes conferring metal resistance.

Removal of vanadium(III) and molybdenum(V) from wastewater using Posidonia oceanica (Tracheophyta) biomass

The use of dried and re-hydrated biomass of the seagrass Posidonia oceanica was investigated as an alternative and –low-cost biomaterial for removal of vanadium(III) and molybdenum(V) from wastewaters. Initial characterisation of this biomaterial identified carboxylic groups on the cuticle as potentially responsible for cation sorption, and confirmed the toxic-metal bioaccumulation. The combined effects on biosorption performance of equilibrium pH and metal concentrations were investigated in an ideal single-metal system and in more real-life multicomponent systems. There were either with one metal (vanadium or molybdenum) and sodium nitrate, as representative of high ionic strength systems, or with the two metals (vanadium and molybdenum). For the single-metal solutions, the optimum was at pH 3, where a significant proportion of vanadium was removed (ca. 70%) while there was ca. 40% adsorption of molybdenum. The data obtained from the more real-life multicomponent systems showed that biosorption of one metal was improved both by the presence of the other metal and by high ionic strength, suggesting a synergistic effect on biosorption rather than competition. There data ware used for the development of a simple multi-metal equilibrium model based on the non-competitive Langmuir approach, which was successfully fitted to experimental data and represents a useful support tool for the prediction of biosorption performance in such real-life systems. Overall, the results suggest that biomass of P. oceanica can be used as an efficient biosorbent for removal of vanadium(III) and molybdenum(V) from aqueous solutions. This process thus offers an eco-compatible solution for the reuse of the waste material of leaves that accumulate on the beach due to both human activities and to storms at sea.