A review of metal recovery from spent petroleum catalysts and ash

Recovery technology of spent hydrogenation catalysts -A review

Spent hydrogenation catalysts (HDCs) contain many Mo, V, Co, Ni, and Al2O3 carriers, which are valuable secondary resources. However, improper disposal can also lead to environmental pollution risks. In the past decade, research reviews on the recovery of valuable metals from spent HDCs have been somewhat reported, mainly summarizing basic technical processes. Based on previous work, this article reviews the emerging recycling technologies of spent HDCs in recent years. The research trend of furnace optimization in the pyrometallurgical process was innovatively proposed, and the importance of developing new mild leaching agents for the high-quality recycling of Al2O3 carriers in the hydrometallurgical process was clarified.

Organic acid-mediated leaching kinetics study and selective extraction of Mo, V, and Ni from spent catalysts

This article employs six organic acids to selectively dissolve Mo, Ni and V from spent catalysts, and the most effective acid is identified. Then, the effects of key leaching parameters, including acid concentration, temperature, and S/L ratio, on metal leaching are systematically explored to determine the leaching mechanism. The results demonstrate that the leaching ability of organic acids followed the order: oxalic acid > citric acid > tartaric acid > malonic acid > acetic acid > formic acid. The leaching process of metals was jointly influenced by acidolysis and complexolysis. Among them, more than 93.07 % of Mo, 86.64 % of V, and 74.21 % of Ni were selectively leached with oxalic acid at the optimum condition: S/l: 1/20, oxalic acid: 1.0 mol/L, temp: 60 °C. From the correlation coefficients, the resulting activation energies, and n values, it was demonstrated that Mo and V followed the Avrami dissolution reaction model, V leaching was controlled by the diffusion mode, and Mo leaching was controlled by a mixed mode of chemical reaction and diffusion. The dissolution behavior of both metals consistently adhered to the linear trend of the Avrami kinetic model under varying S/L ratios and oxalic acid concentrations.

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.

Study on the Regeneration of Waste FCC Catalyst by Boron Modification

Regeneration has been considered as an ideal way for the post-treatment of waste FCC catalyst (ECat). In this work, the degeneration mechanism of ECat was firstly researched and attributed to the increasing of strong acid sites accessibility of ECat in contrast with fresh FCC catalyst by adsorption FTIR. Based on the proposed degeneration mechanism, ECat was successfully regenerated through suitable weakening for strong acid sites by boron modification. Characterization and evaluation results suggested that, the strong acid sites of regenerated ECat (R-ECat) were apparently decreased by boron modification which had significantly improve the heavy oil catalytic cracking performance of R-ECat. Because of the excellent performance, R-ECat in this work could successfully substitute for partial fresh FCC catalyst in FCC unit, which would provide a practicable way for the reutilization of ECat.

A facile method of treating spent catalysts via using solvent for recovering undamaged catalyst support

The process of washing and removing crude oil from spent catalysts is a serious issue in both catalyst regeneration and precious metals recovery. In this work, five different solvents with various polar and aromatic properties were chosen to evaluate their impact on the catalyst support structure and crude oil recovery from oil-contaminated spent catalysts. After the deoiling process, the spent catalyst was analyzed by scanning electron microscopy, X-ray diffraction (XRD), Fourier transform-infrared spectroscopy, elemental analyzer, contact angle measurement, gas chromatography-mass spectrometry, inductively coupled plasma-atomic emission spectroscopy, and Brunauer Emmet Teller (BET) method. Our findings demonstrate that p-xylene and kerosene are more effective in removing oil than other solvents. This is due to crude oil's similar polarity and molecular nature with kerosene and p-xylene. Considering the economical reason, kerosene is a better choice for deoiling spent catalyst compared to p-xylene as it is more affordable than p-xylene. XRD data show that the structure of the catalyst support was unaltered by the solvent treatment process, while BET data reveals that the surface area and pore volume are significantly enhanced after the deoiling process. These results imply that deoiling is a very crucial step for the recycling, regeneration, and reuse of spent catalysts. Our work is significant in developing sustainable approaches for managing spent catalysts, and minimizing waste and environmental pollution.

Bioleaching of the α-alumina layer of spent three-way catalysts as a pretreatment for the recovery of platinum group metals

Acid bioleaching of Al by Acidithiobacillus thiooxidans has been explored as an environmentally friendly pretreatment to facilitate the extraction of platinum group metals from spent three-way catalysts (TWC). Biogenic sulfur obtained from desulfurization bioreactors improved the production of acid by A. thiooxidans compared to commercially available elemental sulfur. The lixiviation abilities of bacteria-free biogenic acid and biogenic acid with exponential or stationary phase bacteria were compared against a control batch produced by commercial H2SO4. The maximum Al leaching percentage (54.5%) was achieved using biogenic acids with stationary-phase bacteria at a TWC pulp density of 5% w/v whereas bacteria-free biogenic acid (23.4%), biogenic acid with exponential phase bacteria (21.7%) and commercial H2SO4 (24.7%) showed lower leaching abilities. The effect of different pulp densities of ground TWC (5, 30, and 60% w/v) on Al leaching and bacterial growth was determined. While greater Al leaching yields were obtained at lower TWC pulp density solutions (54.5% at 5% w/v and 2.5% at 60% w/v), higher pulp densities enhanced microbial growth (2.3 × 109 cells/mL at 5% w/v and 9.5 × 1010 cells/mL at 60% w/v). The dissolution of the metal from the solid into the liquid phase triggered the production of biological polymeric substances that were able to absorb traces of both Al (up to 24.80% at 5% w/v) and Pt (up to 0.40% at 60% w/v).

Thermodynamic analysis and application for extracting valuable components from iron-phosphorus residue of spent catalysts

The method of extracting valuable metals from spent catalysts has been developed in recent years. In this paper, the solid waste produced in the treatment of spent catalyst was studied and named iron-phosphorus residue (IPR). IPR was composed of FePO4·2H2O, Fe3(PO4)2·3H2O, Fe5(PO4)4(OH)3·2H2O, and SiO2. Appreciable quantities of Ni, Co, V, Mo, and W were detected in IPR. Based on E-pH diagrams, different atmospheric leaching strategies were used to extract valuable components from IPR. Both the HCl and NaOH leaching are appropriate for treating IPR. An in-depth investigation on HCl atmospheric leaching showed that >95% of Fe, Ni, Co, V, and Mo, 76.9% of W, and 89.3% of P were extracted efficiently and SiO2 was enriched into the leach residue, at leaching temperature of 90 ℃, leaching time of 180 min, initial HCl concentration of 5 mol/L and liquid to solid ratio of 8:1 mL/g. The leaching mechanism was discussed via XRD, XPS, and FTIR. An efficient and green process for the recovery of valuable components in IPR has been developed. This research achieves the sufficient extraction of valuable components in IPR and provides significant guidance for the management of similar solid waste.

Industrial-Scale Technology for Molybdic Acid Production from Waste Petrochemical Catalysts

The article describes the technology of molybdic acid recovery from spent petrochemical catalysts (HDS) developed and implemented in industrial activity. HDS catalysts contain molybdenum in the form of MoO3 and are used for the hydrodesulfurization of petroleum products. After deactivation, due to the impurities content in the form of sulfur, carbon and heavy metals, they constitute hazardous waste and, at the same time, a valuable source of the Mo element, recognized as a critical raw material. The presented technology allows the recovery of molybdic acid with a yield of min. 81%, and the product contains min. 95% H2MoO4. The technology consisted of oxidizing roasting of the spent catalyst, then leaching molybdenum trioxide with aqueous NaOH to produce water-soluble sodium molybdate (Na2MoO4), and finally precipitation of molybdenum using aqueous HCl, as molybdic acid (H2MoO4). Industrial-scale testing proved that the technology could recover Mo from the catalyst and convert it into marketable molybdic acid. This proves that the technology can be effectively used to preserve molybdenum.

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.

High-value utilisation of PGM-containing residual oil: Recovery of inorganic acids, potassium, and PGMs using a zero-waste approach

Residual oil containing platinum group metals (PGMs), which is under-researched, can easily pose resource waste and environmental risks. PGMs feature as scarce strategic metals, and inorganic acids and potassium salts are also considered valuable. An integrated process for the harmless treatment and recovery of useful resources from residual oil is proposed herein. This work developed a zero-waste process based on the study of the main components and characteristics of the PGM-containing residual oil. The process consists of three modules: pre-treatment for phase separation, liquid-phase resource utilisation, and solid-phase resource utilisation. Separating the residual oil into liquid and solid phases allows for the maximum recovery of valuable components. However, concerns about the accurate determination of valued components emerged. Findings revealed that Fe and Ni are highly susceptible to spectral interference in the PGMs test when using the inductively coupled plasma method. After studying 26 PGM emission lines, Ir 212.681 nm, Pd 342.124 nm, Pt 299.797 nm, and Rh 343.489 nm were reliably identified. Finally, formic acid (81.5 g/t), acetic acid (117.2 kg/t), propionic acid (291.9 kg/t), butyric acid (3.6 kg/t), potassium salt (553.3 kg/t), Ir (27.8 g/t), Pd (10960.0 g/t), Pt (193.1 g/t), and Rh (109.8 g/t) were successfully obtained from the PGM-containing residual oil. This study provides a helpful reference for the determination of PGM concentrations and high-value utilisation of PGM-containing residual oil.

Recovery of vanadium and nickel from heavy oil fly ash (HOFA): a critical review

Heavy oil fly ash "HOFA" is the fly ash generated in power stations using heavy oil as fuel. HOFA is considered a hazardous waste because it contains considerable amounts of heavy metals. However, it contains significant amounts of vanadium "V" and nickel "Ni", which are precious metals for manufacturing processes. This paper presents a critical review of various approaches described in the literature for the recovery of V and Ni from HOFA, including processes of leaching, chemical precipitation, solvent extraction, and ion exchange. The optimum operational parameters and their effects on recovery efficiency are discussed. The digestion mixtures of strong mineral acids used for dissolving all metals present in HOFA are also highlighted. The leaching processes of V and Ni use mainly acidic and alkaline solutions. Bioleaching is a promising environmentally friendly approach for the recovery of V and Ni through using appropriate bacteria and fungi. After leaching, V and Ni compounds are recovered and purified using various techniques, including chemical precipitation, solvent extraction, and ion exchange. In most cases, V and Ni are recovered as thermally decomposable compounds that undergo calcination to produce V₂O₅ and NiO. Eventually, V and Ni are recovered as pure oxides in most approaches, but pure metals are obtained in exceptional procedures.

A novel method for extraction of platinum from spent automotive catalyst: utilization of spent fluid catalytic cracking catalyst as flux

A novel method of smelting of mixture of spent automotive catalyst (SAC) and spent fluid catalytic cracking catalyst (SFCC) to recover platinum and prepare glass slag was investigated. Compared to other metals collection processes for single hazardous waste solid, this method reduced the amount of fluxing materials addition and increased the processing types of hazardous solid waste simultaneously. The optimum SFCC addition, iron collector addition, Na₂B₂O₄•10H₂O addition, CaO/SiO₂ mass ratio, temperature, and holding time for platinum recovery were 20, 11, 16 wt%, 0.6, 1550-1600°C, and 60 min, respectively. In this proposed combined process, more than 98% of platinum is efficiently recovered from SAC. Meanwhile, the concentration of platinum in glass slag was less than 7 g/t. The leaching characteristics of heavy metals in slag confirmed the obtained glass slag is a non-hazardous slag due to the low leaching rate of heavy metal ions. This article proposed an effective and environmentally friendly method for the recovery of platinum from SAC via a combined smelting process.

High Value-Added Utilization of Waste Hydrodesulfurization Catalysts: Low-Cost Synthesis of Cathode Materials for Lithium-Ion Batteries

This work introduces a one-step method for the preparation of layered oxide cathode materials utilizing pure Ni and Co mixed solution obtained from the waste hydrodesulfurization (HDS) catalyst. An efficient non-separation strategy with pyrometallurgical-hydrometallurgical (pyro-hydrometallurgical) process consisting of roasting and leaching is proposed. Most of the impurity metal elements such as Mo and V were removed by simple water leaching after the waste HDS catalyst was roasted with Na2CO3 at 650 °C for 2.5 h. Additionally, 93.9% Ni and 100.0% Co were recovered by H2SO4 leaching at 90 °C for 2.5 h. Then, LiNi0.533Co0.193Mn0.260V0.003Fe0.007Al0.004O2 (C–NCM) was successfully synthesized by hydroxide co-precipitation and high temperature solid phase methods using the above Ni and Co mixed solution. The final C–NCM material exhibits excellent electrochemical performance with a discharge specific capacity of 199.1 mAh g−1 at 0.1 C and a cycle retention rate of 79.7% after 200 cycles at 1 C. This novel process for the synthesis of cathode material can significantly improve production efficiency and realize the high added-value utilization of metal resources in a waste catalyst.

Development of a novel chelation-based recycling strategy for the efficient decontamination of hazardous petroleum refinery spent catalysts

The conventional hydrometallurgical methods for recycling refinery spent hydroprocessing catalysts are ineffective in simultaneously removing all metals (Ni, V, and Mo) in a single-stage operation. In this study, a novel octadentate chelating agent, diethylenetriaminepentaacetic acid (DTPA-C₁₄H₂₃N₃O₁₀), has been proposed for the first time to remove toxic metals (Ni, V, and Mo) in a single stage of operation from an industrial spent atmospheric residue desulfurization (ARDS) catalysts. It was discovered that the efficient formation of metal-DTPA complexes was attained under the optimum experimental conditions (60 °C, stirring - 150 rpm, S/L ration (w/v) of 2.5%, 7.5% DTPA, and medium pH-9) that resulted in the high removal of Mo (83.6%), V (81.3%) and Ni (64.1%) from the spent ARDS catalyst. Kinetic studies suggest that the leaching process followed a semi-empirical Avrami equation (R² > 0.92), which predicted that the diffusion control reaction controlled the leaching. Species distribution and ecological risk analysis of the remaining metals in the insoluble residue (mostly Al₂O₃) indicated that the potential bioavailability of the remaining metals (except Ni) was significantly decreased, and residue poses a low ecological and contamination risk (individual contamination factor <1). Furthermore, the textural properties of the residue (BET surface area-103 m²/g and pore volume- 0.49 ml/g) were dramatically improved, suggesting that fresh hydroprocessing catalyst support can be synthesized using the leached residue. Compared to the conventional processes, the proposed chelating process is highly selective, closed-loop, and achieved high metal recovery in a single-stage operation while decreasing the environmental risks of the hazardous spent catalysts.

Pressure Leaching of Copper Slag Flotation Tailings in Oxygenated Sulfuric Acid Media

In this study, a hydrometallurgical method for the recovery of copper, cobalt, and zinc from copper slag flotation tailings (SFT) was investigated. SFT contains large amounts of valuable metallic compounds, such as copper, cobalt, and zinc. A representative SFT sample containing 0.50% Cu, 0.148% Co, 3.93% Zn, and 39.50% Fe was used in experimental studies. High-pressure oxidative acid leaching of SFT was carried out to assess the effects of sulfuric acid concentration, oxygen partial pressure, reaction time, solid/liquid ratio, and temperature on the extraction of copper, cobalt, zinc, and iron. The dissolution of metals from the SFT sample increased with temperature and sulfuric acid concentration. However, high acid concentrations and high solid/liquid (S/L) ratios led to gel formation that caused filtration problems and inhibited metal dissolution. The optimum leaching conditions were found to be a leaching time of 90 min, an acid concentration of 250 kg/t, a temperature of 220 °C, an S/L ratio of 1:5, and an oxygen partial pressure of 0.7 MPa. Under these conditions, 93.1 ± 1.1% Cu, 96.3 ± 1.8% Co, and 92.3 ± 1.7% Zn were extracted. Iron dissolution was only 0.5 ± 0.1%. This hydrometallurgical process almost completely recovers valuable metals. In particular, cobalt, which is of great importance in the production of lithium-ion batteries, has been declared a critical metal by the United States, Canada, and the EU and was taken into solution with very high extraction efficiency (>95%). Additionally, oxygen partial pressure enhanced copper, cobalt, and zinc dissolution. When O2 was not introduced into the leaching system, the extraction efficiencies of Co, Cu, and Zn were approximately 24.5, 5.3, and 26.3%, respectively, after 2 h of leaching treatment.

Utilization of amino acid for selective leaching of critical metals from spent hydrodesulfurization catalyst

While spent catalysts can cause serious environmental pollution, they can be considered an essential secondary metal source due to their high critical metal grades. The formation of the amino acid-metal complex is often seen in nature, and its potential application in hydrometallurgy can be foreseen. Alanine (Ala) was first screened as the most effective type of amino acid to be used for the selective leaching of spent hydrodesulfurization catalyst (consisting of MoS₂ and Co₃S₄ supported on Al₂O₃, at 10% Mo and 2.4% Co grades). The sequential 3-step leaching (Step-1: Alkaline Ala leaching at 45°C, Step-2: Hot water leaching at 70°C, Step-3: Second alkaline Ala leaching at 45°C) was conducted where the role of Ala was found to be at least three-fold; 1) maintaining alkalinity by amino acid’s buffering capacity to assist Mo leaching, 2) selectively precipitating Co by forming Co-Ala complex with a distinctive pink color, which can readily re-dissolve in hot water to be separated from spent catalyst particles. 3) Effectively suppressing unwanted dissolution of Al throughout the reaction without needing pH control. Consequently, highly metal-selective, two separate Co-rich (<1% Mo and 79% Co dissolved, Al not detected) and Mo-rich (96% Mo, 19% Co, and 2.1% Al dissolved) leachates were obtained. This study highlighted the potential utility of amino acids as non-toxic, alternative metal lixiviant as well as a metal precipitant for selective leaching of critical metals from spent hydrodesulfurization catalyst.

Characteristics and factors that influence heavy metal leaching from spent catalysts

With the extensive use of nonferrous metals and metal catalysts, solid wastes containing heavy metals release metal ions into soil and surface water through erosion and leaching. This is one of the major threats to the global environment and human health. Studying the characteristics and impact factors of heavy metal leaching from solid waste is a critical part of managing spent catalysts and environmental risk. In this work, the characteristics of and factors that influence leaching and seepage release from typical spent catalysts and lead-zinc smelting slag were studied. The results indicated that metal ions leached more easily in an acidic environment (pH 4.5) and an environment with DOM than in a neutral environment (pH 7.0). Metal ion leaching was favored by a liquid-to-solid ratio of 20:1. The concentrations of metal ions released from the spent catalysts in sequential leaching experiments were higher than those in column leaching experiments. Leaching of metal ions in the presence of different leaching agents and from different spent catalysts can be described by different controlling models of the shrinking core model, but changes in the liquid-to-solid ratio showed no obvious correlation with changes in the metal release mechanism. These results provide important information for spent catalyst management and risk prevention and control.

Bioleaching of Heavy Metals by Streptomyces avermitilis - BBA4 Isolate from Coal Mine Soil of Tamil Nadu

Printed Circuit Board (PCB) includes precious metals, heavy metals and brominated flame retardants. The usage of PCB is increasing exponentially, generated in vast quantities, and considered an E-waste contaminating the environment. The bioleaching potential of a novel isolated Streptomyces BBA4 strain from a coal mine soil was studied and discussed here. A total of twelve isolates were isolated from coal mine soil (Neyveli area). The metal-resistant activity of the isolated cultures was examined using a dot plot and agar well diffusion assay. Both assays revealed that the isolate BBA4 showed resistance and survival ability in the copper (Cu) and chromium (Cr)-rich environment up to 1000 mg/kg and in the iron (Fe) and silver (Ag)-rich environment up to 500 mg/kg, respectively. Based on the phenotypic, physiological, biochemical and molecular characteristics, the novel and potential strain (BBA4) isolated from coal mine soil matched with Streptomyces avermitilis. The strain showed bioleaching ability to recover 73.3% Cobalt and 36.4% Chromium within 120 h under pH 5 (in vitro conditions) from the PCB. The heavy metal content in the PCB was analyzed using quantitative analytical techniques, such as Atomic Absorption Spectroscopy (AAS) and Powder X-ray diffraction (XRD). The analysis of XRD peaks exhibited an increase in crystallinity with the Cr, associated with the accumulation of Cr in the bioleached residues. Thus, generated data from this investigation reveal that BBA4 is an effective bioleaching strain on PCB over other environmentally hazardous chemical leaching methods.

Vanadium recovery by electrodialysis using polymer inclusion membranes

Industrial applications and environmental awareness recently prompted vanadium recovery spell from secondary resources. In this work, a polymer inclusion membrane containing trioctylmethylammonium chloride as carrier was successfully employed in electrodialysis for vanadium recovery from acidic sulfate solutions. The permeability coefficient of V(V) increased from 0.29 µm·s^-1 (without electric field) to 4.10 µm·s^-1 (with the 20 mA·cm^-2 current density)_. The transport performance of VO₂SO₄^-, which was the predominant species containing V(V) in the acidic region (pH <3), was influenced by the aqueous pH value and sulfate concentration. Under an electric field, a low concentrated H₂SO₄ solution (0.2 M) effectively stripped V(V) from the membranes, avoiding the requirement of a highly concentrated H₂SO₄ without electric field. Under the optimum conditions, the permeability coefficient and flux reached 6.80 µm·s^-1 and 13.34 µmol·m^-2·s^-1, respectively. High selectivity was observed for the separation of V(V) and Mo(VI) from mixed solutions of Co (II), Ni (II), Mn (II), and Al (III). Additionally, the separation between Mo(VI) and V(V) was further improved by adjusting the acidity of the stripping solution. The V(V) selectivity for the resulting membrane was higher than that of commercial anion exchange membranes.

A Review on Pyrometallurgical Extraction of Antimony from Primary Resources: Current Practices and Evolving Processes

Antimony is classified as a critical/strategic metal. Its primary production is predominated by China via pyrometallurgical routes such as volatilization roasting—reduction smelting or direct reduction smelting. The performance of most of the pyro-processes is very sensitive to concentrate type and grade. Therefore, technology selection for a greenfield plant is a significant and delicate task to maximize the recovery rate of antimony and subsequently precious metals (PMs), mainly gold, from the concentrates. The current paper reviews the conventional pyrometallurgical processes and technologies that have been practiced for the treatment of antimony concentrates. The blast furnace is the most commonly used technology, mainly because of its adaptability to different feeds and grades and a high recovery rate. In addition, several other more environmentally friendly pyrometallurgical routes, that were recently developed, are reviewed but these are still at laboratory- or pilot-scales. For example, decarbonization of antimony production through the replacement of carbonaceous reductants with hydrogen seems to be feasible, although the process is still at its infancy, and further research and development are necessary for its commercialization. At the end, available refining methods for removal of the most important impurities including arsenic, sulfur, lead, iron, and copper from crude antimony are discussed.

Selective Leaching of Valuable Metals from Spent Fluid Catalytic Cracking Catalyst with Oxalic Acid

The problem of spent fluid catalytic cracking (SFCC) catalyst resource utilization, draws more and more attention to system analysis. SFCC was leached in an oxalic solution for comprehensive utilization. The results showed that for a D50 ≤ 17.34 μm, the catalyst leached for 240 min at 95 °C in the presence of a 2 mol/L oxalic acid solution, and the extent of leaching of V, Ni, Fe, and Al was 73.4%, 32.4%, 48.2%, and 36.8%, respectively. Studies on the occurrence state of the main ions (V, Ni, Fe, and Al) in the leaching solution were presented. Additionally, the separation of the main ions from such a solution by the “solvent extraction-stripping-hydrothermal precipitation-comprehensive recovery of valuable metal” process was studied. The immobilization rates of vanadium and nickel in geopolymers can be obtained using the toxicity characteristic leaching procedure (TCLP) test, and the geopolymers prepared by SFCC leaching residues can be considered a non-hazardous material. A process diagram of the comprehensive utilization of SFCC catalysts is presented.

Feasibility of bioleaching integrated with a chemical oxidation process for improved leaching of valuable metals from refinery spent hydroprocessing catalyst

Bioleaching is considered an eco-friendly technique for leaching metals from spent hydroprocessing catalysts; however, the low bioleaching yield of some valuable metals (Mo and V) is a severe bottleneck to its successful implementation. The present study reported the potential of an integrated bioleaching-chemical oxidation process in improved leaching of valuable metals (Mo and V) from refinery spent hydroprocessing catalysts. The first stage bioleaching of a spent catalyst (coked/decoked) was conducted using sulfur-oxidizing microbes. The results suggested that after 72 h of bioleaching, 85.7% Ni, 86.9% V, and 72.1% Mo were leached out from the coked spent catalyst. Bioleaching yield in decoked spent catalyst was relatively lower (86.8% Ni, 79.8% V, and 59.8% Mo). The low bioleaching yield in the decoked spent catalyst was attributed to metals' presence in stable fractions (residual + oxidizable). After first stage bioleaching, the integration of a second stage chemical oxidation process (1 M H₂O₂) drastically improved the leaching of Ni, Mo, and V (94.2-100%) from the coked spent catalyst. The improvement was attributed to the high redox potential (1.77 V) of the H₂O₂, which led to the transformation of low-valence metal sulfides into high-valence metallic ions more conducive to acidic bioleaching. In the decoked spent catalyst, the increment in the leaching yield after second stage chemical oxidation was marginal (<5%). The results suggested that the integrated bioleaching-chemical oxidation process is an effective method for the complete leaching of valuable metals from the coked spent catalyst.

Environmental friendly approach for selective extraction and recovery of molybdenum (Mo) from a sulphate mediated spent Ni-Mo/Al2O3 catalyst baked leach liquor

Solvent extraction separation of molybdenum (Mo) from the sulphate mediated leach solution bearing Aluminium (Al) and Nickel (Ni) was carried out using N-Methyl-N, N, N-tri-octyl-ammonium chloride. Extensive investigation for extraction study molybdenum in the function of time, Eq.pH, extractant concentration, diluents, temperature, strip solution concentration and phase ratio(A:O) for both extraction and stripping was examined to attain a suitable condition on its selective and enriched extraction. As per the equilibrium study and increasing trend of Eq. pH (pH_e) at the correspondence initial pH, it was apparent about association of 1 mol of H⁺ ion during extraction which with was further supported on extraction of Mo as HMO₄^- at the pH_e of 3.48. The association of 1 mol of exrractant during the extraction of Mo was also well evident from the slope analysis study. This indicates about anion exchange phenomenon due to Cl^- ion of the N-Methyl-N, N, N-tri-octyl-ammonium chloride (extractant) with HMo₄^- from aqueous phase during complex formation reaction. The FTIR of the organic sample before and after extraction further confirms in support of the complex formation of the molybdenum with the extractant during extraction. The extraction isotherm was constructed at optmum extraction condition: pH_e of 3.48 with 0.08M N-Methyl-N, N, N-tri-octyl-ammonium chloride predicts on need of 2-counter current stages for quantitative extraction of Mo at A:O = 3:1. To investigate the regeneration behaviour of adopted extractant along with enriched stripping of molybdenum, ammoniacal reagents were used in stripping study. The stripping of Mo showed promising and efficient using the mixture of the ammoniacal reagents (NH₄OH + NH₄Cl) over the either of the solo reagents. The stripping Mc-Cabe Thiele diagram was plotted using 2M NH₄OH + NH₄Cl ensures on quantitative stripping of Mo at SO: SS = 2:1 at 2 no. of stages. Both extraction and stripping isotherm results are validated at predicted isotherm conditions by 6-cycles counter current simulation (CCS) study leading to obtain 6-fold enrichment of Mo in stripped solution phase. The subsequent enriched content of Mo (∼60 g/L) in stripped solution phase was precipitated out followed by calcinations 400 °C to obtain a high pure MoO₃. The recovered calcined product as MoO₃ resulted through the proposed processing approach was as ascertained from XRD analysis.

Extraction of Lanthanum Oxide from Different Spent Fluid Catalytic Cracking Catalysts by Nitric Acid Leaching and Cyanex 923 Solvent Extraction Methods

A laboratory-scale procedure was developed to obtain lanthanum oxide from spent fluid catalytic cracking catalyst, commonly used in the heavy crude oil cracking process. Two different solids, consisting mainly of silica, alumina, and a certain amount of rare earth elements, were leached under several conditions to recover the rare earths. Nitric acid leaching lead to the highest recovery of lanthanum, reaching a recovery percentage greater than 95% when a 1.5 M concentration was used. Subsequently, liquid phases were subjected to a liquid–liquid extraction process using Cyanex 923 diluted in Solvesso 100, and the lanthanum was quantitatively extracted. Lanthanum was also quantitatively stripped using oxalic acid to obtain the corresponding lanthanum oxalates, as revealed by X-ray diffraction (XRD), thermogravimetric analysis (TGA), differential thermal analysis (DTA), and Fourier transform infrared (FTIR) techniques. After thermal treatment at 1200 °C for 2 h, these solids yielded lanthanum oxide.

On the Potential of a Poly(vinylidenefluoride-co-hexafluoropropylene) Polymer Inclusion Membrane Containing Aliquat® 336 and Dibutyl Phthalate for V(V) Extraction from Sulfate Solutions

A polymer inclusion membrane (PIM) composed of 50 wt% base polymer poly(vinylidenefluoride-co-hexafluoropropylene), 40 wt% extractant Aliquat^® 336, and 10 wt% dibutyl phthalate as plasticizer/modifier provided the efficient extraction of vanadium(V) (initial concentration 50 mg L⁻¹) from 0.1 M sulfate solutions (pH 2.5). The average mass and thickness of the PIMs (diameter 3.5 cm) were 0.057 g and 46 μm, respectively. It was suggested that V(V) was extracted as VO₂SO₄⁻ via an anion exchange mechanism. The maximum PIM capacity was estimated to be ~56 mg of V(V)/g for the PIM. Quantitative back-extraction was achieved with a 50 mL solution of 6 M H₂SO₄/1 v/v% of H₂O₂. It was assumed that the back-extraction process involved the oxidation of VO₂⁺ to VO(O₂)⁺ by H₂O₂. The newly developed PIM, with the optimized composition mentioned above, exhibited an excellent selectivity for V(V) in the presence of metallic species present in digests of spent alumina hydrodesulfurization catalysts. Co-extraction of Mo(VI) with V(V) was eliminated by its selective extraction at pH 1.1. Characterization of the optimized PIM was performed by contact angle measurements, atomic-force microscopy, energy dispersive X-ray spectroscopy, thermogravimetric analysis/derivatives thermogravimetric analysis and stress–strain measurements. Replacement of dibutyl phthalate with 2-nitrophenyloctyl ether improved the stability of the studied PIMs.

Highly efficient selective extraction of Mo with novel hydrophobic deep eutectic solvents

Recycling of valuable metals from spent catalysts in a green way is gaining extensive interest for economic and environment reasons. In this study, we developed novel hydrophobic deep eutectic solvents to extract Mo from spent catalysts. The hydrophobic DESs have been designed and synthesized by mixing one molar of the quaternary ammonium salt and two molars of various saturated fatty acids with different carbon chain lengths. The extraction ability and extraction mechanism of these DESs were studied, some factors influencing the extraction efficiency, including the structure of hydrogen bond acceptors and hydrogen bond donors, initial aqueous pH, reaction time and temperature, phase ratios were investigated. It is found that the synthesized hydrophobic DESs exhibit excellent extraction performance toward Mo, where the Mo distribution ratio is more than 2200 in the presence of other metals, corresponding to an extraction efficiency of 99% at optimal reaction conditions. This work reveals a distinct class of materials, guiding an effective and green way for spent catalyst treatment.Implications: Novel hydrophobic deep eutectic solvents have been developed to extract Mo from spent catalysts, the synthesized hydrophobic DESs possess several advantages, such as green, low price, low toxicity, and biodegradability. It exhibits excellent extraction performance under an optimized extraction condition. This work reveals a distinct class of materials, guiding a promising way for green and economical utilization of spent catalysts.

Spent sulfuric acid plant catalyst: valuable resource of vanadium or risky residue? Process comparison for environmental implications

The enormous amount of spent catalysts generated worldwide may pose a risk to the environment because of their high load of metals, including vanadium. The latter may be mobilized and released to the environment if managed improperly. Moreover, the catalysts could be considered as secondary resources rather than waste. This study aimed at the efficient extraction of vanadium from spent desulfurization catalyst (SDC) from a sulfuric acid production plant. The raw SDC and the post-extraction residues were characterized in terms of their chemical and phase composition. The metal mobility from the materials was examined with both single-step and multi-step extractions. The environmental risk assessment was performed using sequential extraction. The study revealed that both tested methods (citric acid leaching and bioleaching with Acidithiobacillus thiooxidans) enable the extraction of nearly 96% of V from SDC with a simultaneous reduction of metal mobility. However, the bacterial treatment was found more suitable. The leached residue was mostly (> 90%) composed of SiO2, which makes it a potential candidate for application in construction (e.g., concrete mixtures) after additional examinations. The study highlights the need to develop a metal extraction process for SDC in a way that metal-free residue could be a final product.

Recovering valuable metals from spent hydrodesulfurization catalyst via blank roasting and alkaline leaching

Spent hydrodesulfurization (HDS) catalysts, containing considerable amount of pollutants and metals including vanadium (V), molybdenum (Mo), aluminum (Al), and nickel (Ni), are considered as hazardous wastes which will result in not only ecosystem damage but also squandering resource. Herein, a process featuring blank roasting-alkaline leaching is proposed to recover spent HDS catalyst. During roasting, low-valence compounds convert to high-valence oxides which can be leached out by NaOH solution. Afterwards, leaching solution is subjected to crystallization to separate metals. The results show that for samples roasted at 650 °C, 97% V, 96% Mo, and 88% Al are leached out at optimal condition; for samples roasted at 1000 °C, selective leaching of 91% V and 96% Mo respectively, are realized, with negligible Al being dissolved. NiO is insoluble in strong alkali leaving in residue. The advantages of this process are that first, the leaching of V, Mo, and Al can be manipulated by controlling roasting conditions, providing flexible process design. Second, leaching solution can be fully recycled. Finally, mild leaching condition and clean separation of V, Mo, and Al is achieved, proving fundamental information for peer researches to facilitate their future research on the development of more efficient and cleaner technologies.

A comprehensive review on the applications of functionalized chitosan in petroleum industry

The biomaterials have gained the attention for utilization as sustainable alternatives for petroleum-derived products due to the rapid depletion of petroleum resources and environmental issues. Chitosan is an economical, renewable and abundant polysaccharide having unique molecular characteristics. Chitosan is derived by deacetylation of chitin, a natural polysaccharide existing in insects' exoskeleton, outer shells of crustaceans, and some fungi cell walls. Chitosan is widely used in numerous domains like agriculture, food, water treatment, medicine, cosmetics, fisheries, packaging, and chemical industry. This review aims to account for all the efforts made towards chitosan and its derivatives for utilization in the petroleum industry and related processes including exploration, extraction, refining, transporting oil spillages, and wastewater treatment. This review includes a compilation of various chemical modifications of chitosan to enhance the petroleum field's performance and applicability.

Research on Hazardous Waste Removal Management: Identification of the Hazardous Characteristics of Fluid Catalytic Cracking Spent Catalysts

Fluid catalytic cracking (FCC) spent catalysts are the most common catalysts produced by the petroleum refining industry in China. The National Hazardous Waste List (2016 edition) lists FCC spent catalysts as hazardous waste, but this listing is very controversial in the petroleum refining industry. This study collects samples of waste catalysts from seven domestic catalytic cracking units without antimony-based passivation agents and identifies their hazardous characteristics. FCC spent catalysts do not have the characteristics of flammability, corrosiveness, reactivity, or infectivity. Based on our analysis of the components and production process of the FCC spent catalysts, we focused on the hazardous characteristic of toxicity. Our results show that the leaching toxicity of the heavy metal pollutants nickel, copper, lead, and zinc in the FCC spent catalyst samples did not exceed the hazardous waste identification standards. Assuming that the standards for antimony and vanadium leachate are 100 times higher than that of the surface water and groundwater environmental quality standards, the leaching concentration of antimony and vanadium in the FCC spent catalyst of the G set of installations exceeds the standard, which may affect the environmental quality of surface water or groundwater. The quantities of toxic substances in all spent FCC catalysts, except those from G2, does not exceed the standard. The acute toxicity of FCC spent catalysts in all installations does not exceed the standard. Therefore, we exclude "waste catalysts from catalytic cracking units without antimony-based passivating agent passivation nickel agent" from the "National Hazardous Waste List."

Effect of pulp density on the bioleaching of metals from petroleum refinery spent catalyst

Bioleaching is one of the well-known methods of metal recovery with Environmental benefits. This process has been extensively used for combating improper waste management issues along with metal reclamation. The aim of this study is to bioleach spent petroleum refinery catalyst at variant pulp densities (PD) (5, 10 and 15%) using microorganisms in acidic pH (1.5-1.6) and mesophilic temperature (30-35 °C). The study includes leaching yields of metals like nickel, molybdenum, copper and aluminum. The three bioleaching experiments with different pulp densities yielded a maximum of more than 90% nickel, 73% copper, 87% molybdenum and 24% aluminum. The results are validated 5, 10, and 15% pulp density and the result is validated with pH, Redox potential, microbial population, sulphate concentration and ferrous iron, concentration. The time saving due to faster nickel dissolution using iron and sulphur oxidizing microorganisms would be economical for the bioleaching process.

Fungal bioleaching of metals from refinery spent catalysts: A critical review of current research, challenges, and future directions

Petroleum refining operations such as hydroprocessing and fluid catalytic cracking (FCC) generate huge quantities of spent catalysts containing toxic and valuable metals (Ni, V, Mo, Co, W, Al, etc.), the management of which is a serious environmental issue. Besides environmental concerns, the different metals present in the spent catalysts are also a valuable commodity to modern industries. Therefore, these spent catalysts also provide an opportunity to use it as a source of value to the refiners. In recent years, a biotechnological based leaching process 'bioleaching' has emerged as a promising eco-friendly technique for the extraction of metals from these refinery spent catalysts. Among various bioleaching agents such as archean, bacterial, or fungi, the process mediated by the fungi (Aspergillus niger, Penicillium simplicissimum, and many others) is gaining attention owing to the high metal extraction ability of the various fungal produced metabolites (organic acids) under moderately acidic conditions. Furthermore, the ability of these fungi to withstand wide process conditions (pH, spent catalyst concentration, substrate types, etc.), high metal toxicity and use of low-cost organic substrate make them an ideal candidate for bioleaching. In this review article, we shed light on the role and mechanisms of fungi involved in extracting different metals from spent hydroprocessing and FCC catalysts. Key process parameters that affect the efficiency of fungal based bioleaching are discussed. The techno-economic challenges associated with the process are elaborated, and the needed future research directions to promote its commercial applications are highlighted. Based on our analysis, it can be argued that the fungi bioleaching has potential, however, some challenges (slower kinetics, and health and safety) should be addressed before the process can be scaled up for the commercial application.

Highly efficient recovery of molybdenum from spent catalyst by an optimized process

Disposal of spent catalyst in an economical and green way has become a great concern for industrial production. We developed a process including acid leaching, solvent extraction and stripping in order to recycle spent catalyst. In this study, we conducted selective recovery of molybdenum through focus on finding an optimized extraction and stripping process by comparing different extractants and stripping agents. To separate molybdenum from other metals efficiently and figure out the mechanism of extraction process, the five different extractants of methyl trioctyl ammonium chloride, tri-n-octylamine, tris (2-ethylhexyl) amine, bis (2-ethylhexyl) phosphate, and tributyl phosphate with different functional groups were examined; the extraction ability and extraction mechanism of these five extractants were systematically studied under the same system for the first time. It was found that more than 98% of the molybdenum could be extracted with an organic phase consisting of tri-n-octylamine or methyl trioctyl ammonium chloride under the optimal conditions. The result indicated that the tri-n-octylamine and methyl trioctyl ammonium chloride possess excellent molybdenum extraction ability, the extraction capacity of the rest extractants was in the order of bis (2-ethylhexyl) phosphate > tris (2-ethylhexyl) amine > tributyl phosphate. In the stripping process, NH₄OH, NaOH, and H₂SO₄ were chosen as stripping agent to strip the molybdenum from the loaded tri-n-octylamine organic phase. The stripping ability of the three studied stripping agents was in the order NaOH > NH₄OH > H₂SO₄. The Fourier transform infrared (FTIR) spectra showed that the structure of the tri-n-octylamine organic phase was stable during the extraction and stripping process. Results showed that molybdenum could be highly and efficiently recovered by optimized extraction and stripping process. Implications: A series of different extractants and stripping agent have been systematically studied in order to compare their extraction and stripping ability under the same system. Based on the obtained results, an optimized extraction and stripping process was proposed to recycle molybdenum from spent catalyst efficiently. It is possible to dispose spent catalysts in an economic and environmental way by this developed metal recovery process.

Mercury-bearing wastes: Sources, policies and treatment technologies for mercury recovery and safe disposal

Due to the lenient environmental policies in developing economies, mercury-containing wastes are partly produced as a result of the employment of mercury in manufacturing and consumer products. Worldwide, the presence of mercury as an impurity in several industrial processes leads to significant amounts of contaminated waste. The Minamata Convention on Mercury dictates that mercury-containing wastes should be handled in an environmentally sound way according to the Basel Convention Technical Guidelines. Nevertheless, the management policies differ a great deal from one country to another because only a few deploy or can afford to deploy the required technology and facilities. In general, elemental mercury and mercury-bearing wastes should be stabilized and solidified before they are disposed of or permanently stored in specially engineered landfills and facilities, respectively. Prior to physicochemical treatment and depending on mercury's concentration, the contaminated waste may be thermally or chemically processed to reduce mercury's content to an acceptable level. The suitability of the treated waste for final disposal is then assessed by the application of standard leaching tests whose capacity to evaluate its long-term behavior is rather questionable. This review critically discusses the main methods employed for the recovery of mercury and the treatment of contaminated waste by analyzing representative examples from the industry. Furthermore, it gives a complete overview of all relevant issues by presenting the sources of mercury-bearing wastes, explaining the problems associated with the operation of conventional discharging facilities and providing an insight of the disposal policies adopted in selected geographical regions.

Photocatalytic degradation of methylene blue with spent FCC catalyst loaded with ferric oxide and titanium dioxide

The spent fluid catalytic cracking (FCC) catalyst has been loaded with ferric oxide (Fe2O3) and titanium dioxide (TiO2). Fe-Ti/SF composite (loaded with 5 wt% TiO2 and 5 wt% Fe2O3), Fe/SF composite (loaded with10 wt% Fe2O3) and Ti/SF composite (loaded with 10 wt% TiO2) have been fabricated via a modified-impregnation method. The band gaps of the Fe-Ti/SF, Fe/SF and Ti/SF composites (evaluated by the energy versus [F(R∞)hv]n) are 2.23, 1.98 and 3.0 eV, respectively. Electrochemical impedance spectroscopy shows that the Fe-Ti/SF has lower electron transfer resistance, it has the small charge transfer resistance and fast charge transfer rate. The interparticle electrons transfer between the Fe2O3 and TiO2, which can improve the separation of the photo-electrons and holes. The holes transfer from valence band of TiO2 to the valence band of Fe2O3, which can provide more active sites around the adsorbed molecules. The methylene blue degradation efficiencies (with the Fe-Ti/SF, Fe/SF and Ti/SF composites) are ~ 94.2%, ~ 22.3% and ~ 54.0% in 120 min, respectively. This work reveals that the spent FCC catalyst as supporter can be loaded with Fe2O3 and TiO2. This composite is highly suitable for degradation of methylene blue, which can provide a potential method to dispose the spent FCC catalyst in industry.

Vanadium sustainability in the context of innovative recycling and sourcing development

This paper addresses the sustainability of vanadium, taking into account the current state-of-the-art related to primary and secondary sources, substitution, production, and market developments. Vanadium plays a critical role in several strategic industrial applications including steel production and probable widespread utilization in next-generation batteries. Confirming the importance of vanadium, the European Commission identified and formally registered this metal on the 2017 list of Critical Raw Materials for the European Union. The United States and Canada have also addressed the importance of this metal. Like the European economy, the American and Canadian economies rely on vanadium and are not globally independent. This recognized importance of vanadium is driving many efforts in academia and industry to develop technologies for the utilization of secondary vanadium resources using hydrometallurgical and pyrometallurgical techniques. In this paper, current efforts and their outcomes are summarized along with the most recent patents for vanadium recovery.

Cobalt in end-of-life products in the EU, where does it end up? - The MaTrace approach

The use of cobalt has experienced a strong growth in the last decades. Due to its high economic importance and high supply risk, it has been classified as a critical raw material for the EU and other economies. Part of the EU's strategy is intended to secure its availability, through fostering its efficient use and recycling. The latter is affected by factors such as the amount of available end-of-life products, and their collection-to-recycling rate. A novel methodology to analyze the impact of these factors on the cobalt flows in society is the model MaTrace, which can track the fate of materials over time and across products. The MaTrace model was expanded, adapted, and applied to predict the fate of cobalt embedded in finished products in use in the EU, considering the underlying life cycle phases within the technosphere. Eleven scenarios were built, assessing different options in the implementation of relevant EU's policies. The flows were projected for a period of 25 years, starting in 2015. The results of the baseline scenario show that after 25 years, around 8% of the initial stock of cobalt stays in use, 3% is being hoarded by users, 28% has been exported, and 61% has been lost. The main contributors to the losses of the system are the non-selective collection of end-of-life products, and the export of end-of-life products, recycled cobalt and final products. The results of the scenarios show that higher collection-to-recycling rates and lower export could increase up to 50% the cobalt that stays in use.

Recycle, Recover and Repurpose Strategy of Spent Li-ion Batteries and Catalysts: Current Status and Future Opportunities

The disposal of hazardous waste of any form has become a great concern for the industrial sector due to increased environmental awareness. The increase in usage of hydroprocessing catalysts by petrochemical industries and lithium-ion batteries (LIBs) in portable electronics and electric vehicles will soon generate a large amount of scrap and create significant environmental problems. Like general electronic wastes, spent catalysts and LIBs are currently discarded in municipal solid waste and disposed of in landfills in the absence of policy and feasible technology to drive alternatives. Such inactive catalyst materials and spent LIBs not only contain not only hazardous heavy metals but also toxic and carcinogenic chemicals. Besides polluting the environment, these systems (spent catalysts and LIBs) contain valuable metals such as Ni, Mo, Co, Li, Mn, Rh, Pt, and Pd. Therefore, the extraction and recovery of these valuable metals has significant importance. In this Review, we have summarized the strategies used to recover valuable (expensive) as well as cheap metals from secondary resources-especially spent catalysts and LIBs. The first section contains the background and sources of LIBs and catalyst scraps with their current recycling status, followed by a brief explanation of metal recovery methods such as pyrometallurgy, hydrometallurgy, and biometallurgy. The recent advances achieved in these methods are critically summarized. Thus, the Review provides a guide for the selection of adequate methods for metal recovery and future opportunities for the repurposing of recovered materials.

Sustainable management of spent fluid catalytic cracking catalyst from a circular economy approach

For sustainable growth, an economic model must tend toward a circular system, especially in the field of waste management. This work focuses on the valorization of spent fluid catalytic cracking catalyst from oil refineries, which generate 400,000 metric tons of spent catalyst per year worldwide, most of which is sent to landfills. A new alternative to landfilling is proposed for this waste, based on the combination of acid leaching for the recovery of lanthanum, a valuable rare earth, and the reuse of the leached solid residue as a cement substitute. A comparative life cycle assessment was made, including four environmental impact categories, i.e. global warming, fossil resource scarcity, mineral resource scarcity and water consumption, in order to quantify the potential environmental benefits of secondary lanthanum recovery from industrial waste with respect to primary lanthanum extraction from mineral resources. A maximum of 85.6% La recovery was achieved and 15 wt% of cement can be substituted with leached solid residue without changing the original cement classification. The waste management process presented in this paper promotes the sustainable management of the spent fluid catalytic cracking catalyst and contributes to the development of a new resource for a critical material such as lanthanum. The implementation of this novel waste management process could reduce global warming and mineral resource scarcity but would increase fossil resource scarcity and water consumption in comparison with primary La extraction.

Data quality assessment framework for critical raw materials. The case of cobalt

Critical Raw Materials (CRMs) require a deep understanding of their societal metabolism, for which robust data and information are needed. However, despite the efforts to build reliable data, some CRMs such as cobalt, are still characterised by lack of data harmonization, lack of connection between datasets, and significant data unavailability. Together with data gaps filling, data quality is a crucial aspect to improve Material Flow Analysis (MFA) and Criticality Assessment (CA). Nevertheless, most of the methodologies for Data Quality Assessment (DQA) are not designed for these tools, but for others, e.g. life cycle assessment. The current research addresses the following challenges; a better understanding of the societal metabolism of CRMs; the development and implementation of DQA in MFA and CA; and a better understanding of the available data related to current cobalt flows in the EU technosphere. The underlying life cycle phases of CRMs within the technosphere were identified, together with 15 key parameters. A new DQA matrix was developed, which was subsequently applied to the full dataset collected for cobalt. The dataset was built considering seven high-end applications of cobalt. More than 300 values were gathered, which were analysed in function of different aspects, such as the country/region, and year. Through the data analysis and the application of the DQA framework, data gaps were identified due to low availability and/or low quality. It was concluded that the main deficiency of cobalt data is its reliability, due to lack of information regarding its generation method, and the incomplete stakeholder coverage.

Enfoques microbiológicos para el tratamiento de catalizadores agotados

Los catalizadores, homogéneos o heterogéneos, son ampliamente utilizados para una gran variedad de procesos industriales, con el fin de producir combustibles limpios y muchos otros productos valiosos, siendo los catalizadores agotados provenientes del hidroprocesamiento los mayores residuos sólidos de la industria de la refinería y la contribución principal a la generación de catalizadores agotados. Debido a su naturaleza peligrosa, el tratamiento y la recuperación de metales de este tipo de residuos han ganado cada vez más importancia, debido al agotamiento de los recursos naturales y a la contaminación ambiental. Aunque ya existen técnicas disponibles para estos fines, éstas generan grandes volúmenes de desechos potencialmente peligrosos y producen emisiones de gases nocivos. Por lo tanto, las técnicas biotecnológicas pueden representar una alternativa promisoria para el biotratamiento y la recuperación de metales contenidos en los catalizadores agotados. Con este fin, se han analizado diversos microorganismos, que comprenden bacterias, arqueobacterias y hongos, capacitados para facilitar la eliminación de losmetales contenidos en estoscatalizadores. En estarevisión se presenta un amplio escenario sobre los avances con respecto al manejo de los catalizadores agotados y su tratamiento tradicional, seguido de una descripción detallada sobre los enfoques microbiológicos reportados hasta la actualidad.