Application of rare earths in fluid catalytic cracking: A review

Quantitative evaluation of anthropogenic sources and health risks of rare earth elements in airborne particulate matter

Rare earth elements (REEs) have emerged as contaminants in airborne particulate matter (PM); however, their anthropogenic sources remain poorly quantified, and associated health risks are unknown. This study investigates the REE distribution across eight sizes of airborne PM during July and December in Qingdao, a major Chinese port city. Our results reveal a single coarse-mode distribution with REE concentrations. In contrast, fine PM (size: 0.43-2.1 μm) exhibits notable enrichment of La and Ce compared to Al and other REEs. This study traces La and Ce enrichment to fluid catalytic cracking catalysts (FCCC)-related sources, including refinery and ship emissions, by comparing the REE fractionation in samples with potential sources. We quantify the contributions from FCCC-related sources to La (July: 33.6 % ± 3.2 %, Dec.: 46.4 % ± 5.2 %) and Ce (July: 16.5 % ± 14.3 %, Dec.: 30.3 % ± 12.2 %) by comparing measured concentrations with predictions derived from neighboring REEs, a method previously used exclusively in aquatic systems. For the first time, supply ratios of refinery and ship to FCCC-related La are calculated using a two-component mixing model based on the [La]FCCC/[V]anth, revealing the dominance of refinery emissions (July: 97.3 % ± 0.6 %, Dec.: 99.6 % ± 0.1 %). Furthermore, a global review of La and Ce anomalies that integrates published REE data with our findings reveals a widespread distribution of positive anomalies. The significantly positive correlation between La and Ce anomalies underscores FCCC-related emissions as a global source in fine PM, contributing 0-92 % (mean: 35 % ± 33 %) for La and 0-72 % (mean: 21 % ± 24 %) for Ce. Although the non-carcinogenic health risks of Ce are generally low globally, concerns should be raised in areas near source emissions, where Ce health risks sharply increased along with its concentrations. There is urgently need to establish a threshold value for La, owing to its global enrichment. This study provides novel insights into the sources and health implications of REEs in airborne PM.

Recycling of Spent FCC Catalysts: Conversion of Leached Residues to Zeolite ZSM-5

The commercial recycling of spent FCC catalyst typically focuses on recovering only 1-3 % of rare-earth elements, with the remaining residues often disposed of in landfills. Here, we present a novel method to close a recycling loop for spent FCC catalyst. The method involves a series of leaching steps: Firstly, the spent catalyst material is leached with HNO3 to remove rare-earth elements such as La; second, solvothermal leaching with HCl removes most of Al and impurities like Fe, Ni and V; finally, a third leaching with H2SO4 removes Ti. The solid residues are then used to synthesize ZSM-5 without the addition of any extra silicon or aluminum sources after mild activation. The impurities in the synthesis gel strongly modify the properties of the zeolite, with ZSM-5 crystals containing higher levels of impurities exhibiting lower crystallinities, surface areas, acidities, cracking activities, as well as larger particle sizes.

Stabilization of Pr4+ in Silicates─High-Pressure Synthesis of PrSi3O8 and Pr2Si7O18

The reaction between PrO2 and SiO2 was investigated at various pressure points up to 29 GPa in a diamond anvil cell using laser heating and in situ single-crystal structure analysis. The pressure points at 5 and 10 GPa produced Pr2III(Si2O7), whereas Pr4IIISi3O12 and Pr2IV(O2)O3 were obtained at 15 GPa. Pr4IIISi3O12 can be interpreted as a high-pressure modification of the still unknown orthosilicate Pr4III(SiO4)3. PrIVSi3O8 and Pr2IVSi7O18 that contain praseodymium in its rare + IV oxidation state were identified at 29 GPa. After the pressure was released from the reaction chamber, the Pr(IV) silicates could be recovered, indicating that they are metastable at ambient pressure. Density functional theory calculations of the electronic structure corroborate the oxidation state of praseodymium in both PrIVSi3O8 and Pr2IVSi7O18. Both silicates are the first structurally characterized representatives of Pr4+-containing salts with oxoanions. All three silicates contain condensed networks of [SiO6] octahedra which is unprecedented in the rich chemistry of lanthanoid silicates.

Rare Earths-The Answer to Everything

Rare earths, scandium, yttrium, and the fifteen lanthanoids from lanthanum to lutetium, are classified as critical metals because of their ubiquity in daily life. They are present in magnets in cars, especially electric cars; green electricity generating systems and computers; in steel manufacturing; in glass and light emission materials especially for safety lighting and lasers; in exhaust emission catalysts and supports; catalysts in artificial rubber production; in agriculture and animal husbandry; in health and especially cancer diagnosis and treatment; and in a variety of materials and electronic products essential to modern living. They have the potential to replace toxic chromates for corrosion inhibition, in magnetic refrigeration, a variety of new materials, and their role in agriculture may expand. This review examines their role in sustainability, the environment, recycling, corrosion inhibition, crop production, animal feedstocks, catalysis, health, and materials, as well as considering future uses.

Capturing Rare-Earth Elements by Synthetic Aluminosilicate MCM-22: Mechanistic Understanding of Yb(III) Capture

We studied the mechanism underlying the solid-phase adsorption of a heavy rare-earth element (HREE, Yb) from acidic solutions employing MCM-22 zeolite, serving as both a layered synthetic clay mimic and a new platform for the mechanistic study of HREE adsorption on aluminosilicate materials. Mechanistic studies revealed that the adsorption of Yb(III) at the surface adsorption site occurs primarily through the electrostatic interaction between the site and Yb(III) species. The dependence of Yb adsorption on the pH of the solution indicated the role of surface charge, and the content of framework Al suggested that the Brønsted acid sites (BAS) are involved in the adsorption of Yb(III) ions, which was further scrutinized by spectroscopic analysis and theoretical calculations. Our findings have illuminated the roles of surface sites in the solid-phase adsorption of HREEs from acidic solutions.

Synthesis and catalytic behavior of FCC catalysts obtained from kaolin by the in-situ method

In-situ zeolites NaY and Na[B]Y were synthesized on microspherical matrices of kaolin to obtain FCC catalysts. An alkaline pretreatment of the matrix was investigated in order to evaluate its effect on matrix properties and crystallization of the in-situ synthetized zeolites. Catalysts were characterized by SEM, TEM, Ar adsorption, XRD and NH3-TPD. It was observed an increase in the surface area and mesoporosity of the alkaline treated catalysts either synthetized with the presence of boron or with no boron in the hydrothermal reaction mixture. Ammonia TPD analyses have shown an increase in the amount and strength of the acidity of the catalysis with the zeolites crystallized on the pretreated matrices and exchanged with lanthanum ions. Thus, a combination between higher concentration of stronger acid sites and higher proportion of mesoporous generated in the matrices treated with alkaline solution had resulted in more active catalyst as shown by the triisopropylbenzene cracking experiments conducted here.

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Ho2O3-TiO2 Nanobelts Electrode for Highly Selective and Sensitive Detection of Cancer miRNAs

The design and engineering of effective electrode materials is critical in the development of electrochemical sensors. In the present study, Ho2O3-TiO2 nanobelts were synthesized by an alkaline hydrothermal process. The structure and morphology were investigated by X-ray diffraction (XRD) and field emission scanning electron microscope (FESEM) measurements. The Ho2O3-TiO2 nanobelts showed a distinctly enhanced (004) reflection peak and rough surfaces and were used for the electrochemical selective sensing of various cancer miRNAs, such as prostate cancer miR-141, osteosarcoma miR-21, and pancreatic cancer miR-1290. Voltammetric measurements showed an oxidation peak at +0.4, +0.2, and +1.53 V for the three different cancer biomarkers, respectively, with the detection limit as low as 4.26 aM. The results suggest that the Ho2O3-TiO2 nanobelts can be used as active materials to detect early cancers, for in vitro screening of anticancer drugs, and molecular biology research.

Efficient Catalytic Conversion of Glucose into Lactic Acid over Y-β and Yb-β Zeolites

In this work, a new type of modified β zeolites with rare earth elements (ree) was discovered for producing lactic acid from glucose and achieved a good catalytic effect. At first, the catalytic performances of ree-β zeolites, ree oxides, and single-transition-metal-β zeolites were compared, and the result showed that Y-β and Yb-β zeolites had the best catalytic activity under the same reaction conditions. Under the best reaction conditions, the maximum yields of lactic acid with Y-β and Yb-β catalysts were 45.3 and 43.6%, respectively. The acid characterization showed that Y/Yb-β zeolites had a similar number of Lewis acid sites as Sn-β zeolites, and they were also more than other transition-metal-β zeolites. Thus, Y-β and Yb-β zeolites had a higher lactic acid yield than those catalysts. It is interesting to note that Y-β and Yb-β zeolites owned more Brønsted acids but produced fewer byproducts. Combining the decomposition experiment of 5-hydroxymethyl furfural, fewer byproducts were produced with Y-β and Yb-β zeolites because the low amount of Brønsted acid contained could hinder the decomposition of 5-hydroxymethyl furfural, thereby slowing down the side reaction.

Modeling and equilibrium studies on the recovery of praseodymium (III), dysprosium (III) and yttrium (III) using acidic cation exchange resin

In this research, the possibility of using hydrogenated Dowex 50WX8 resin for the recovery and separation of Pr(III), Dy(III) and Y(III) from aqueous nitrate solutions were carried out. Dowex 50WX8 adsorbent was characterized before and after sorption of metal ions using Fourier-transform infrared spectroscopy (FT-IR), Scanning Electron Microscope (SEM) and Energy Dispersive X-Ray Analysis (EDX) techniques. Sorption parameters were studied which included contact time, initial metal ion concentration, nitric acid concentration and adsorbent dose. The equilibrium time has been set at about 15.0 min. The experimental results showed that the sorption efficiency of metal ions under the investigated conditions decreased with increasing nitric acid concentration from 0.50 to 3.0 M. The maximum sorption capacity was found to be 30.0, 50.0 and 60.0 mg/g for Pr(III), DY(III) and Y(III), respectively. The desorption of Pr(III) from the loaded resin was achieved with 1.0 M citric acid at pH = 3 and found to be 58.0%. On the other hand, the maximum desorption of Dy(III) and Y(III) were achieved with 1.0 M nitric acid and 1.0 M ammonium carbonate, respectively. The sorption isotherm results indicated that Pr(III) and Y(II) fitted with nonlinear Langmuir isotherm model with regression factors 0.995 and 0.978, respectively; while, Dy(III) fitted with nonlinear Toth isotherm model with R² = 0.966. A Flow sheet which summarizes the sorption and desorption processes of Pr(III), DY(III) and Y(III) using Dowex 50WX8 from nitric acid solution under the optimum conditions is also given.

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.

Insight into the Nature and the Transformation of the Hydroxyl Species in the CeY zeolite

The nature and the transformation of each potential hydroxyl species in a Ce-modified Y zeolite during the calcination process have been investigated via the information of the hydroxyl spectra of...

Rare earth elements in plastics

Because of their unique properties, rare earth elements (REEs), comprising the lanthanide elements plus Sc and Y, have a variety of integral applications in modern electronic equipment. Consequently, it has been suggested that REEs may act as contaminants of and tracers for recycled electrical and electronic plastics in consumer goods. In this study, REEs have been determined in a range of consumer plastics of different polymeric makeup (n = 31), and purchased new and in societal circulation, by inductively coupled plasma-mass spectrometry following acid digestion. Samples were also screened by X-ray fluorescence spectrometry for Br and Sb as markers of brominated flame retardants and the retardant synergist, Sb₂O₃, respectively. One or more REE was detected in 24 samples, with four samples returning detectable concentrations of all REEs analysed and with total REE concentrations up to 8 mg kg^-1. REEs were most commonly observed in samples containing Br and Sb at levels insufficient to effect flame retardancy and, therefore, likely derived from recycled electronic plastic, but were not detectable in new electrical plastics. Various REEs were also present in plastics with no detectable Br and Sb, however, and where unregulated recycling is prohibited (e.g. food packaging). This observation, and correlations between pairs of REEs for all samples considered, suggests a more generic source of these elements in consumer plastics in addition to the recycling of electrical and electronic waste. REEs reported in the literature for beached marine plastics were characterised by similar concentrations and inter-element correlations, suggesting that REEs are ubiquitous and pervasive contaminants of both contemporary and historical consumer and environmental plastics.

Development of semi-synthetic catalyst based on clay and their use in catalytic cracking of petroleum residue

Two semi-synthetic clay-based catalysts were prepared. These catalysts were obtained by incorporating lanthanum oxide (Cat1) and chromium oxide (Cat2). They were then tested for catalytic cracking of a heavy petroleum residue (fuel). The two formulations were carried out in the presence of silica to improve their acidity then underwent an acid activation. The catalysts obtained were characterized by various methods (XRD, FTIR, ICP-OES, SEM). The results showed that the incorporation of oxides and the addition of silica improves the structural characteristics of the final products. The support used was a kaolinite rich clay, having a specific surface area of 15.26 m2/g and acidity of 14 meq/g. These values increase, respectively, to 456.14 m2/g and 50 meq/g for Cat1 and to 475.12 m2/g and 57 meq/g for Cat2. The influence of the type of oxide incorporated, the specific surface area, the porosity and the acidity of the catalysts on their catalytic activity was studied. The nature of the oxide used proved to be decisive on the quality of the catalyst. Thus Cat1, prepared with lanthanum oxide, showed the best performance in cracking the petroleum residue achieving a conversion rate of 74.13% compared to 66.53% for cat2.

Single-Atom Catalysts across the Periodic Table

Isolated atoms featuring unique reactivity are at the heart of enzymatic and homogeneous catalysts. In contrast, although the concept has long existed, single-atom heterogeneous catalysts (SACs) have only recently gained prominence. Host materials have similar functions to ligands in homogeneous catalysts, determining the stability, local environment, and electronic properties of isolated atoms and thus providing a platform for tailoring heterogeneous catalysts for targeted applications. Within just a decade, we have witnessed many examples of SACs both disrupting diverse fields of heterogeneous catalysis with their distinctive reactivity and substantially enriching our understanding of molecular processes on surfaces. To date, the term SAC mostly refers to late transition metal-based systems, but numerous examples exist in which isolated atoms of other elements play key catalytic roles. This review provides a compositional encyclopedia of SACs, celebrating the 10th anniversary of the introduction of this term. By defining single-atom catalysis in the broadest sense, we explore the full elemental diversity, joining different areas across the whole periodic table, and discussing historical milestones and recent developments. In particular, we examine the coordination structures and associated properties accessed through distinct single-atom-host combinations and relate them to their main applications in thermo-, electro-, and photocatalysis, revealing trends in element-specific evolution, host design, and uses. Finally, we highlight frontiers in the field, including multimetallic SACs, atom proximity control, and possible applications for multistep and cascade reactions, identifying challenges, and propose directions for future development in this flourishing field.

Recovering Secondary REE Value from Spent Oil Refinery Catalysts Using Biogenic Organic Acids

Spent catalysts produced by oil refinery industries are regarded as an important secondary source for valuable metals. In particular, spent fluid catalytic cracking (FCC) catalysts represent a potential source for rare earth elements (REEs). This study aimed to exploit the leachability of spent FCC catalysts as a secondary source for La, by using an alternative organic acid lixiviant produced under optimized fungal fermentation conditions. The first chemical leaching tests revealed that citric acid (>100 mM) is a comparable alternative lixiviant to conventional inorganic acids (1 M) and that the La dissolution behavior changed significantly with different types of organic acids. The initial fungal fermentation conditions (e.g., inoculum level, substrate concentration, pH) largely affected the resultant biogenic acid composition, and its manipulation was possible in order to almost solely ferment citric acid (~130 mM) while controlling the production of unwanted oxalic acid. The performance of actual biogenic acids (direct use of cell-free spent media) and artificially reconstituted biogenic acids (a mixture of chemical reagents) was nearly identical, achieving a final La dissolution of ~74% at a pulp density of 5%. Overall, the microbiological fermentation of organic acids could become a promising approach to supply an efficient and environmentally benign alternative lixiviant for REE scavenging from spent FCC catalyst wastes.

Effect of V2O5 Additive on Micro-Arc Oxidation Coatings Fabricated on Magnesium Alloys with Different Loading Voltages

Effect of V2O5 additive in silicate-containing electrolyte on AZ91D magnesium alloys treated by micro-arc oxidation (MAO) technology under different loading voltages was investigated. The results showed that vanadium was well up-taken into the coating chemically. Moreover, a new phase of MgV2O4 with spinel structure was obtained in MAO coatings due to V2O5 added into the electrolyte. The MgV2O4 phase was responsible for the coatings exhibiting brown color and also was beneficial to improving the anti-corrosion property. In spotting tests, the corrosion resistances of coatings prepared under the high voltage are about 6–9 times higher than those of the low voltage because of the thicker coatings of the former. In potentiodynamic polarization tests, the coatings’ corrosion resistances were improved with the addition of V2O5, which was more significant under the low voltage than that under the high voltage. When the concentration of V2O5 was 0.2 g/L, the corrosion current density of the coating was the lowest, which means that the coating’s corrosion resistance under the low voltage is the best. Hence, it is necessary to carry out targeted design of the coating’s microstructure according to the different applications.

APD Compressible Aerogel-Like Monoliths with Potential Use in Environmental Remediation

Ambient pressure dried (APD) silica-based aerogel-like monoliths are prepared using vinyltrimethoxysilane (VTMS) as the sole silicon source by a rare-earth-assisted process. The APD method avoids the processes of solvent exchange and surface modification, is cost-effective, and reduces the preparation period from several days or weeks to 30 h. By controlling the solvent proportions, products with excellent mechanical properties, including exceptional mechanical strength and elasticity, can be synthesized. The monoliths also exhibit the outstanding characteristics of high hydrophobicity and lipophilicity and can rapidly absorb 13.5 times their weight in chloroform, showing great potential as reusable materials for application toward the separation/extraction of organic pollutants and oils.

Fuel production by cracking of polyolefins pyrolysis waxes under fluid catalytic cracking (FCC) operating conditions

The catalytic cracking of high-density polyethylene pyrolysis waxes under fluidized catalytic cracking conditions has been investigated with the aim of producing fuels at large-scale from waxes obtained in pyrolysis plants located nearby collection and segregation points. Additionally, preliminary information about the capacity of these units to valorize waste polyolefins has been obtained. The catalytic cracking runs have been performed in a riser simulator reactor under industrial conditions: 500-560 °C; catalyst to oil mass ratio, 3, 5 and 7 g_cat g_oil^-1; and, contact time, 6 s. The product distribution has been quantified determining the yields of different fractions, which have been defined according to their boiling point range: dry gas, liquefied petroleum gas, naphtha, light cycle oil, heavy cycle oil and coke. The concentration of the families of compounds has been also determined, which are n-paraffins, iso-paraffins, olefins, naphthenes and aromatics. For the shake of comparison, the results of catalytic cracking of a common stream fed to the industrial units, i.e., vacuum gasoil, have been included. Globally, promising results have been obtained in the valorization of waste polyolefins by means of this combination of pyrolysis-cracking stages that expose, at the same time, the capacity of this unit to manage waste plastics.

Transformations of FCC catalysts and carbonaceous deposits during repeated reaction-regeneration cycles

Transformations of an industrial zeolite-based fluid catalytic cracking (FCC) catalyst and its coke deposits during regeneration following FCC reactions of a representative refinery stream are investigated.

Spent FCC E-Cat: Towards a Circular Approach in the Oil Refining Industry

Every year the oil refining industry consumes thousand tons of fluid catalytic cracking zeolite from the E-cat generated in the fluid catalytic cracking (FCC) unit. In the present paper, a new process for recycling of fluid catalytic cracking catalysts (FCCCs) is presented. The process, previously tested at laboratory scale, was simulated by SuperPro Designer catalysts (FCCCs, also known as equilibrium catalysts, E-cat), which are mainly landfilled. Their intrinsic value is quite low and the content of rare earth elements (REEs), as lanthanum and cerium oxides, is around 3%wt. Moreover, their reuse in other industrial processes as raw material is very scarce. For each metric ton of spent FCCC treated for recovery of REEs, nearly the same amount of waste is generated from the process, the majority of which is represented by the solid residue resulting from the leaching stage. The manuscript presents a technological study and an economic analysis for the recovery of REEs, as well as the production of synthetic © software package. The plant was designed for a capacity of 4000 metric tons per year. The discounted cash flow (DCF) method was applied and Net Present Value (NPV) equal to about two-million € and Discounted Payback Time (DPBT) equal to two years defined the profitability of the process for recycling of FCCCs. This result depends on the selling price of zeolite. Consequently, a break-even point (BEP) analysis was conducted on this critical variable and the condition of economic feasibility was verified with a price of 1070 €/ton. This study tried to implement recycling strategies towards circular economy models.

Zeolites as Catalysts for Fuels Refining after Indirect Liquefaction Processes

The use of zeolite catalysts for the refining of products from methanol synthesis and Fisher-Tropsch synthesis was reviewed. The focus was on fuels refining processes and differences in the application to indirect liquefaction products was compared to petroleum, which is often a case of managing different molecules. Processes covered were skeletal isomerisation of n-butenes, hydroisomerisation of n-butane, aliphatic alkylation, alkene oligomerisation, methanol to hydrocarbons, ethanol and heavier alcohols to hydrocarbons, carbonyls to hydrocarbons, etherification of alkenes with alcohols, light naphtha hydroisomerisation, catalytic naphtha reforming, hydroisomerisation of distillate, hydrocracking and fluid catalytic cracking. The zeolite types that are already industrially used were pointed out, as well as zeolite types that have future promise for specific conversion processes.