A review on the recycling processes of spent auto-catalysts: Towards the development of sustainable metallurgy

Optimization of synergistic capturing platinum group metals by Fe-Sn and its mechanism

Platinum group metals (PGMs) are strategic metals. Auto-exhaust catalysts are their main application fields. The recovery of PGMs from spent auto-exhaust catalysts has remarkable economic value and strategic significance. Aiming at the problems of ferrosilicon generation for Fe capturing and subsequent oxygen blowing to remove iron with high energy consumption and heat release, a technology of Fe-Sn synergistic capturing PGMs was proposed. Taking full the advantage of the lower melting point of Fe-Sn alloy (<1200 °C) and its unique affinity for PGMs, the PGMs were captured at approximate 1400 °C with Fe-Sn as the collector. In experiment, 500 g of spent auto-exhaust catalysts were employed to minimize error and approximate industrial production. The mechanism of Fe-Sn synergistic capturing PGMs was elucidated. The generation of Fe-Sn-PGMs alloy lowered the activity of [PGMs] in the system, accelerated the reduction of the PGMs oxides and promoted the alloying of [PGMs]. Therefore, Fe-Sn synergistic capturing PGMs was realized. The inability of Si to enter the alloy phase was confirmed by theoretical calculations, avoiding the generation of ferrosilicon. The effects of basicity, CaF2, m(Fe)/m(Sn) and the amount of collector on capturing PGMs were optimized. Under the optimized conditions (basicity R = 1.1, spent auto-exhaust catalysts 70 wt%, CaO 30 wt%, B2O3 10 wt%, CaF2 7 wt%, m(Fe)/m(Sn) = 1/1 and the collector 15 wt%), the content of PGMs in the slag phase was 2.46 g/t. It is feasible to remove Fe and Sn by oxidation to achieve the purpose of PGMs enrichment. This technology offers guidance on the safe, environmentally sound, and efficient disposal of spent auto-exhaust catalysts, promoting the sustainable development of PGMs.

Solar-assisted selective separation and recovery of precious group metals from deactivated air purification catalysts

The mitigation of environmental and energy crises could be advanced by reclaiming platinum group precious metals (PGMs) from decommissioned air purification catalysts. However, the complexity of catalyst composition and the high chemical inertness of PGMs significantly impede this process. Consequently, recovering PGMs from used industrial catalysts is crucial and challenging. This study delves into an environmentally friendly approach to selectively recover PGMs from commercial air purifiers using photocatalytic redox technology. Our investigation focuses on devising a comprehensive strategy for treating three-way catalysts employed in automotive exhaust treatment. By meticulously pretreating and modifying reaction conditions, we achieved noteworthy results, completely dissolving and separating rhodium (Rh), palladium (Pd), and platinum (Pt) within a 12-h time frame. Importantly, the solubility selectivity persists despite the remarkably similar physicochemical properties of Rh, Pd, and Pt. To bolster the environmental sustainability of our method, we harness sunlight as the energy source to activate the photocatalysts, facilitating the complete dissolution of precious metals under natural light irradiation. This eco-friendly recovery approach demonstrated on commercial air purifiers, exhibits promise for broader application to a diverse range of deactivated air purification catalysts, potentially enabling implementation on a large scale.

Microwave Encounters Ionic Liquid: Synergistic Mechanism, Synthesis and Emerging Applications

Progress in microwave (MW) energy application technology has stimulated remarkable advances in manufacturing and high-quality applications of ionic liquids (ILs) that are generally used as novel media in chemical engineering. This Review focuses on an emerging technology via the combination of MW energy and the usage of ILs, termed microwave-assisted ionic liquid (MAIL) technology. In comparison to conventional routes that rely on heat transfer through media, the contactless and unique MW heating exploits the electromagnetic wave-ions interactions to deliver energy to IL molecules, accelerating the process of material synthesis, catalytic reactions, and so on. In addition to the inherent advantages of ILs, including outstanding solubility, and well-tuned thermophysical properties, MAIL technology has exhibited great potential in process intensification to meet the requirement of efficient, economic chemical production. Here we start with an introduction to principles of MW heating, highlighting fundamental mechanisms of MW induced process intensification based on ILs. Next, the synergies of MW energy and ILs employed in materials synthesis, as well as their merits, are documented. The emerging applications of MAIL technologies are summarized in the next sections, involving tumor therapy, organic catalysis, separations, and bioconversions. Finally, the current challenges and future opportunities of this emerging technology are discussed.

Extraction of platinum group metals from catalytic converters

Platinum group metals (PGMs) assume an important role within the chemistry and chemical engineering due to their exceptional chemical stability in high temperatures and various environmental conditions. Their unique attributes make them highly demanded materials across an array of industries. Nevertheless, the gradual depletion of PGM reserves underscores necessitates of recycling PGM-containing waste as a means to ensure the reasonable utilization of resources. Recycling of catalytic waste, in particular, presents a more cost-effective and environmentally sustainable approach acquiring these metals, in contrast to the conventional practice of mining from natural ores. Of particular importance are spent automotive catalysts, which represent a valuable source of platinum group metals, featuring substantially higher PGM concentrations than their naturally occurring counterparts. Conventionally, the recovering of PGMs from waste materials predominantly employs hydrometallurgical and pyrometallurgical processes. Unfortunately, these established techniques entail the utilization of potent oxidizing acidic solutions, including aqua regia and hydrochloric acid with chlorine gas, which exert adverse ecological consequences. In recent years, there has been a growing focus on the development of alternative methodologies that are both environmentally friendly and economically viable for the recovery of PGMs from spent catalysts. Notable among these emerging techniques are solvometallurgy, molecular recognition technology, and magnetic separation. This comprehensive review endeavors to study and assess the latest advancements in the recovery of platinum group metals from spent catalysts, meticulously evaluating their respective advantages and disadvantages. Through an analysis, this review aspires to identify the most promising method - one that combines environmental friendliness and economic feasibility.

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.

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.

Process and mechanism of enhanced HCl leaching of platinum group metals from waste three-way catalysts by Li2CO3 calcination pretreatment

Recovery of platinum group metals (PGMs) from waste three-way catalysts (TWCs) was usually achieved by dissolving them in an acid solution. However, their dissolution requires the addition of oxidizing agents such as Cl₂ and aqua regia, which could cause high environmental risks. Therefore, the development of new methods without the addition of oxidant agents will contribute to the green recovery of PGMs. In this paper, the process and mechanism of PGMs recovery from waste TWCs by Li₂CO₃ calcination pretreatment-HCl leaching were studied in detail, and molecular dynamics calculations were performed for the formation processes of Pt, Pd, and Rh complex oxides. The results showed that the leaching rates of Pt, Pd, and Rh could reach about 95%, 98%, and 97%, respectively, under the optimal conditions. Li₂CO₃ calcination pretreatment cannot only oxidize Pt, Pd, and Rh metals to HCl-soluble Li₂PtO₃, Li₂PdO₂, and Li₂RhO₃, but also remove the carbon accumulation in waste TWCs and open the wrapping of PGMs by the substrate and Al₂O₃ coating. The embedding of Li and O atoms in metallic Pt, Pd, and Rh is an interacting embedding process. Although the Li atoms are faster than O, O will accumulate on the metal surface first before embedding.

Study on the Mechanism and Experiment of Styrene Butadiene Rubber Reinforcement by Spent Fluid Catalytic Cracking Catalyst

Spent Fluid Catalytic Cracking (FCC) Catalyst is a major waste in the field of the petroleum processing field, with a large output and serious pollution. The treatment cost of these waste catalysts is high, and how to achieve their efficient reuse has become a key topic of research at home and abroad. To this end, this paper conducted a mechanistic and experimental study on the replacement of some carbon blacks by spent FCC catalysts for the preparation of rubber products and explored the synergistic reinforcing effect of spent catalysts and carbon blacks, in order to extend the reuse methods of spent catalysts and reduce the pollution caused by them to the environment. The experimental results demonstrated that the filler dispersion and distribution in the compound are more uniform after replacing the carbon black with modified spent FCC catalysts. The crosslinking density of rubber increases, the Payne effect is decreased, and the dynamic mechanical properties and aging resistance are improved. When the number of replacement parts reached 15, the comprehensive performance of the rubber composites remained the same as that of the control group. In this paper, the spent FCC catalysts modified by the physical method instead of the carbon-black-filled SBR can not only improve the performance of rubber products, but also can provide basic technical and theoretical support to realize the recycling of spent FCC catalysts and reduce the environmental pressure. The feasibility of preparing rubber composites by spent catalysts is also verified.

Sustainable and Selective Modern Methods of Noble Metal Recycling

Noble metals exhibit broad arrange of applications in industry and several aspects of human life which are becoming more and more prevalent in modern times. Due to their limited sources and constantly and consistently expanding demand, recycling of secondary and waste materials must accompany the traditional mineral extractions. This Minireview covers the most recent solvometallurgical developments in regeneration of Pd, Pt, Rh, Ru, Ir, Os, Ag and Au with emphasis on sustainability and selectivity. Processing-by selective oxidative dissolution, reductive precipitation, solvent extraction, co-precipitation, membrane transfer and trapping to solid media-of eligible multi-metal substrates for recycling from waste printed circuit boards to end-of-life automotive catalysts are discussed. Outlook for possible future direction for noble metal recycling is proposed with emphasis on sustainable approaches.

Selective Pd recovery from acidic leachates by 3-mercaptopropylphosphonic acid grafted TiO2: does surface coverage correlate to performance?

Modification of metal oxides with organophosphonic acids (PAs) provides the ability to control and tailor the surface properties. The metal oxide phosphonic acid bond (M-O-P) is known to be stable under harsh conditions, making PAs a promising candidate for the recovery of metals from complex acidic leachates. The thiol functional group is an excellent regenerable scavenging group for these applications. However, the research on organophosphonic acid grafting with thiol groups is very limited. In this study, four different metal sorbent materials were designed with different thiol surface coverages. An aqueous-based grafting of 3-mercaptopropylphosphonic acid (3MPPA) on mesoporous TiO₂ was employed. Surface grafted thiol groups could be obtained in the range from 0.9 to 1.9 groups per nm². The different obtained surface properties were studied and correlated to the Pd adsorption performance. High Pd/S adsorption efficiencies were achieved, indicating the presence of readily available sorption sites. A large difference in their selectivity towards Pd removal from a spend automotive catalyst leachate was observed due to the co-adsorption of Fe on the titania support. The highest surface coverage showed the highest selectivity (K _d: 530 mL g^-1) and adsorption capacity (Q _max: 0.32 mmol g^-1) towards Pd, while strongly reducing the co-adsorption of Fe on remaining TiO₂ sites.

Liquid- and Solid-based Separations Employing Ionic Liquids for the Recovery of Platinum Group Metals Typically Encountered in Catalytic Converters: A Review

The wide application range and ascending demand for platinum group metals combined with the progressive depletion of their natural resources renders their efficient recycling a very important and pressing matter. Primarily environmental considerations associated with state-of-the-art recovery processes have shifted the focus of the scientific community toward the investigation of alternative recycling approaches. Within this context, ionic liquids have gained considerable attention in the last two decades chiefly sparked by properties such as tunabilty, low-volatility, and relatively easy recyclability. In this review an understanding of the state-of-the-art processes, including their drawbacks and limitations, is provided. The core of the discussion is focused on platinum group metal recovery with ionic liquid-based systems. A brief insight in some environmental considerations related to ionic liquids is also provided while some discussion on research gaps, common misconceptions related to ionic liquids and outlook on unresolved issues could not be absent from this review.

A review on management of waste three-way catalysts and strategies for recovery of platinum group metals from them

Platinum group metals (PGMs), especially platinum (Pt), palladium (Pd), and rhodium (Rh), are widely used in automotive three-way catalysts (TWCs). PGM resources are scarce and unevenly distributed, with global reserves of 69,000 t in 2020, of which more than 99% are concentrated in South Africa, Russia, Zambia, and the United States. However, the demand for PGMs worldwide is growing continually, especially in China. The recovery of PGMs from spent TWCs not only can alleviate the contradiction between supply and demand but also have good economic and environmental benefits. This paper briefly analyzes the market demand for Pt, Pd, and Rh in the global automotive industry in recent years, emphasizing the importance of waste TWC recycling. It also presents the current status of waste TWC management in some countries, especially China, and critically reviews the main recycling strategies for waste TWCs. On this basis, suggestions for strengthening the management of waste TWCs in China are put forward, and the future development trend of recycling technology is foreseen. The purpose of this paper is to provide some valuable references for the decision-makers of waste TWC management, and hopefully to provide inspiration for related scholars on the future research direction of waste TWC recycling technology.

Slag design and iron capture mechanism for recovering low-grade Pt, Pd, and Rh from leaching residue of spent auto-exhaust catalysts

Recovery of platinum group metals (PGMs) from secondary resources has attracted worldwide attention from environmental and economic points of view. Pyrometallurgical routes exhibit the superiority in terms of efficiency and contamination control compared to hydrometallurgical process. However, traditional pyrometallurgical processes face the challenges of excessive flux and energy consumption. In this paper, an iron capture process was proposed to recover low-grade PGMs from leaching residue of spent auto-exhaust catalysts. Slag design was explored aimed at reducing the addition amount of flux. The optimized smelting conditions were as follows: 1400 °C for 30 min, adding 40.0 wt% CaO, 22.7 wt% Na₂CO₃, 5.0 wt% Na₂B₄O₇, 5.0 wt% CaF₂, 15.0 wt% Fe, and 5.0 wt% C. The concentrations of Pt, Pd and Rh remaining in the smelting slag were 0.83 g/t, 4.99 g/t, and 1.47 g/t, respectively. Furthermore, the 50 kg-scale experiment implied positive economic feasibility because of saving flux dosage and smelting time. The capture mechanism was revealed by investigating the formation of the metals phase and slag phase. Matrix formed slag phase and separate with metals phase owing to differences in chemical bonding, density, viscosity, and surface tension. PGMs were proved solubilized in α-Fe as substitutional solid solutions. The formation energies for FePt, FePd, and FeRh alloys were -4.149 eV, -4.040 eV, and -4.360 eV, respectively. Finally, the obtained CaO-SiO₂-Al₂O₃-Na₂O glass slag was used for producing glass ceramics. To sum up, the iron capture process realized low energy and material consumption, high recovery efficiency of PGMs, and resource utilization of the glass slag.

Recovery of Platinum-Group Metals from an Unconventional Source of Catalytic Converter Using Pressure Cyanide Leaching and Ionic Liquid Extraction

The fast depletion of critical metals in natural reserves against their increasing demands in advanced technology application presents the necessity to exploit the end-of-life/waste materials as unconventional resources. Due to a higher accumulation of platinum-group metals (PGMs) in exhausted autocatalytic converters, their recycling through an integrative bio-solvo-chemical technique has been studied. PGMs were efficiently dissolved in bio-cyanide solution produced by Chromobacterium violaceum. The autoclave leaching was optimized in the conditions of temperature, 150°C; pO₂, 200 psi; and time, 120 min, yielding > 90% PGMs' dissolution. PGMs' separation from cyanide leach liquor was performed using an ionic liquid, Cyphos IL101. Under optimum conditions (i.e., ionic liquid concentration, 0.15 mol/L; extraction pH, 10.4; and temperature, 25°C), Pt and Pd were selectively stripping with > 99% efficiency in 0.1 mol/L (acidic) thiourea and 1.0 mol/L HNO₃ solution, respectively, leaving Rh in the raffinate.

From Waste to Green Applications: The Use of Recovered Gold and Palladium in Catalysis

The direct use in catalysis of precious metal recovery products from industrial and consumer waste is a very promising recent area of investigation. It represents a more sustainable, environmentally benign, and profitable way of managing the low abundance of precious metals, as well as encouraging new ways of exploiting their catalytic properties. This review demonstrates the feasibility and sustainability of this innovative approach, inspired by circular economy models, and aims to stimulate further research and industrial processes based on the valorisation of secondary resources of these raw materials. The overview of the use of recovered gold and palladium in catalytic processes will be complemented by critical appraisal of the recovery and reuse approaches that have been proposed.

First of Its Kind Automotive Catalyst Prepared by Recycled PGMs-Catalytic Performance

The production of new automotive catalytic converters requires the increase of the quantity of Platinum Group Metals in order to deal with the strict emission standards that are imposed for vehicles. The use of PGMs coming from the recycling of spent autocatalysts could greatly reduce the cost of catalyst production for the automotive industry. This paper presents the synthesis of novel automotive Three-Way Catalysts (PLTWC, Pd/Rh = 55/5, 60 gPGMs/ft3) and diesel oxidation catalysts (PLDOC, Pt/Pd = 3/1, 110 gPGMs/ft3) from recovered PGMs, without further refinement steps. The catalysts were characterized and evaluated in terms of activity in comparison with benchmark catalysts produced using commercial metal precursors. The small-scale catalytic monoliths were successfully synthesized as evidenced by the characterization of the samples with XRF analysis, optical microscopy, and N2 physisorption. Hydrothermal ageing of the catalysts was performed and led to a significant decrease of the specific surface area of all catalysts (recycled and benchmarks) due to sintering of the support material and metal particles. The TWCs were studied for their activity in CO and unburned hydrocarbon oxidation reactions under a slightly lean environment of the gas mixture (λ > 1) as well as for their ability to reduce NOx under a slightly rich gas mixture (λ < 1). Recycled TWC fresh catalyst presented the best performance amongst the catalysts studied for the abatement of all pollutant gases, and they also showed the highest Oxygen Storage Capacity value. Moreover, comparing the aged samples, the catalyst produced from recycled PGMs presented higher activity than the one synthesized with the use of commercial PGM metal precursors. The results obtained for the DOC catalysts showed that the aged PLDOC catalyst outperformed both the fresh catalyst and the aged DOC catalyst prepared with the use of commercial metal precursors for the oxidation of CO, hydrocarbons, and NO. The latter reveals the effect of the presence of several impurities in the recovered PGMs solutions.

Platinum Recovery Techniques for a Circular Economy

Platinum and other metals are very scarce materials widely used in the energy and transportation sector among other sectors. Obtaining Platinum is becoming more difficult due to its scarcity on earth and because of the high amount of energy and water used for its extraction. In this regard, the recycling of platinum is necessary for sustainable technologies and for reaching a circular economy towards this expensive and rare metal. Conventional methods for platinum recycling make use of enormous amounts of energy for its recovery, which makes them not very attractive for industry implementation. Furthermore, these processes generate very toxic liquid streams and gas wastes that must be further treated, which do not meet the green environmental point of view of platinum recycling. Consequently, new advanced technologies are arising aiming to reach very high platinum recovery rates while being environmentally friendly and making a huge reduction of energy use compared with the conventional methods. In this review, conventional platinum recovery methods are summarized showing their limitations. Furthermore, new and promising approaches for platinum recovery are reviewed to shed light on about new and greener ways for a platinum circular economy.

Clean production and utilisation of hydrogen in molten salts

Green and low cost production of strategic materials such as steel and graphene at large scale is a critical step towards sustainable industrial developments. Hydrogen is a green fuel for the future, and a key element for the clean production of steel. However, the sustainable and economic production of hydrogen is a barrier towards its large scale utilisation in iron and steelmaking, and other possible applications. As a key challenge, the water electrolysis, which is commonly used for the carbon-free production of hydrogen, is uneconomic and involves various problems including the corrosion of equipment, the use of expensive catalysts and high over-potentials, limiting its viability. Moreover, the hydrogen transportation from the electrolyser to the utilisation unit is problematic in terms of cost and safety. From a thermodynamic point of view, the potential and efficiency of the water splitting process can greatly be improved at high temperatures. Therefore, a practical approach to resolve the above-mentioned shortcomings can be based on the electro-generation of hydrogen in high temperature molten salts, and the utilisation of the generated hydrogen in situ to produce metals, alloys or other commercially valuable materials. Clean production of alloy powders is particularly interesting due to the rising of advanced manufacturing methods like additive manufacturing. The hydrogen produced in molten salts can also be used for the large scale preparation of high value advanced carbon nanostructures such as single and multi-layer high quality graphene and nanodiamonds. The combination of these findings can lead to the fabrication of hybrid structures with interesting energy and environmental applications. Surprisingly, the production of a large variety of materials such as Fe, Mo, W, Ni and Co-based alloys should be achievable by the electrolytic hydrogen produced in molten salts at a potential of around 1 V, which can easily be powered by advanced photovoltaic cells. This review discusses the recent advancements on these topics.