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.

Closed-loop process for selective leaching and recovery of palladium from spent auto-exhaust catalysts using iodotrihalide ionic liquids

The recovery of palladium from spent auto-exhaust catalysts (SAE-catalysts) is of great significance for resource sustainability. Herein, we proposed an efficient closed-loop leaching and recovery method for palladium from SAE-catalysts using iodotrihalide ionic liquids (ILs). Recovery design was explored aimed at green leaching and process simplification. Iodotrihalide ILs exhibited exceptional performance in terms of leaching efficiency (99.1%), selectivity (selectivity > 6.8 ×103) and reusability (over 6 cycles). The mechanism study revealed that excellent leaching performance was attributed to the redox and complexation. Additionally, the chemical reaction-controlled model was best suited to describe the leaching process. Notably, under the optimal conditions determined by the response surface methodology, a high-purity Pd(II) solution (purity > 99.8%) was obtained. More significantly, it was ideal for practical applications due to the low-viscosity (36.0 cP), mild (55 °C) and one-step leaching and recovery. In conclusion, this work provides an eco-friendly method for recovering palladium from SAE-catalysts with its non-high corrosiveness and low environmental impact.

Extensive investigation on extraction and leaching kinetics study of Cu and Cr from spent catalyst using acetic acid

The application of organic acids towards the extraction of both Cu and Cr from the Cu-Cr spent catalyst was investigated. A series of organic acid such as acetic acid, citric acid, formic acid, ascorbic acid and tartaric acid were adopted, and after screening, acetic acid showed a profound effect on dissolution of either of the metals over other green reagents. The spent catalyst was characterized by XRD and SEM-EDAX to confirm the existence of the oxide phase due to both Cu and Cr metals. For efficient dissolution of metals, the critical parameters such as agitation speed, acetic acid concentration, temperature, particle size, as well as S/L ratio affecting on it was systematically investigated. It was observed that at approximately 99.99% of Cu along with 62% of Cr was extracted at the optimised conditions (agitation speed: 800 rpm, 1.0 M CH3COOH, 353 K temperature, particle size of (75-105) µm and S/L: 2% (W/V). The leach residue obtained after the first stage of leaching was analysed by SEM-EDAX and XRD, indicating no peaks due to the presence of Cu ensures complete dissolution of Cu at the optimum conditions. Further, to attain the quantitative leaching yield of Cr, the leach residue obtained after the first stage was sequentially investigated using varied acetic acid concentration and temperature. Leaching kinetics was established based on obtained results at the varied operating parameters, and it revealed support for fitting a model of the leaching data to the shrinking core chemical control model (R2 = 0.99) for both metals (Cu and Cr). The activation energy determined to be 34.05 kJ mol-1 and 43.31 kJ mol-1 for Cu and Cr, respectively, validates the proposed leaching kinetics mechanism.

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.

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.

Sequential-Anaerobic and Sequential-Aerobic Bioleaching of Metals (Ni, Mo, Al and V) from Spent Petroleum Catalyst in Stirred Tank Batch Reactor: A Comparative Study

Spent petroleum catalyst as a repository of several toxic metals is recommended for metal removal before safe disposal. To evaluate an effective biotechnological approach for metal removal, a comparative study between sequential-aerobic and sequential-anaerobic bioleaching processes was conducted for the removal of metals from crushed-acetone-pretreated spent petroleum catalyst. The SEM-EDX and XPS analysis confirmed the presence of Ni, Al, Mo and V in their oxidic and sulphidic forms in spent catalyst. The bioleaching experiments were performed in stirred tank batch reactors (2.5 L), temperature 30 °C, pH 1.4 and stirring speed 250 rpm for the period of 160 h. Sulfuric acid acted as lechant for both sequential-aerobic (Acidithiobacillus ferrooxidans oxidised sulfur to sulfuric acid aerobically) and sequential-anaerobic (Acidithiobacillus ferrooxidans oxidised sulphur to sulfuric acid coupled with the ferric reduction to ferrous anaerobically) bioleaching studies. The higher Ni and V extractions compared to Al and Mo for all the studies were due to increased solubility of Ni and V, and supported by XPS which showed marginal signs of Ni and V peaks in leach residues compared to feed spent catalyst. At the end (320 h), sequential-aerobic bioleaching was resulted to 99% Ni, 65% Al, 90% Mo and 99% V extraction quite more effective than sequential-anaerobic bioleaching (88% Ni, 28% Al, 33% Mo and 77% V) and sequential-control leaching (94% Ni, 20% Al, 40% Mo and 57% V). Although anaerobic bioleaching a possible approach, aerobic condition was found to be more suitable for sulfuric acid generation by A. ferrooxidans and high yield. So aerobic bioleaching is recommended to be favourable approach compared to anaerobic counterpart for future study and extrapolation.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s12088-021-00978-8.

Generation behavior of extracellular polymeric substances and its correlation with extraction efficiency of valuable metals and change of process parameters during bioleaching of spent petroleum catalyst

The vital functions of extracellular polymeric substances (EPS) have been well recognized in bioleaching of sulfide ores. However, no report is available about the role of EPS in bioleaching of spent catalyst. To completely and deeply understand the functions of EPS in bioleaching of spent catalyst, the generation behavior of EPS at various pulp densities during bioleaching was characterized by three-dimensional excitation-emission matrix (3DEEM), and its relevance with bioleaching performance and process parameters were analyzed using mathematical means. The results showed that the EPS contain humus-like substances as main component (>70%) and protein-like substances as minor component (<30%). Both total EPS and humus-like substances mainly keep growing over the whole duration of bioleaching at low pulp density of 5.0% or lower; whereas total EPS and humus-like fraction keep declining at high pulp density of 7.5% or higher. Among the total EPS and its components, humus-like substances only have a positive significant correlation with bioleaching efficiencies of both Co and Mo and affect bioleaching process more greatly due to greater correlation coefficient. Biofilm appears at the spent catalyst surface under 2.5% of pulp density mediated by EPS while no biofilm occurs at 10% of pulp density due to shortage of EPS, accounting for the great difference in bioleaching efficiencies between high and low pulp densities which are 48.3% for Mo and 50.0% for Co at 10% of pulp density as well as 75.9% for Mo and 78.8% for Co at 2.5% of pulp density, respectively.

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.

Column bioleaching of metals from refinery spent catalyst by Acidithiobacillus thiooxidans: Effect of operational modifications on metal extraction, metal precipitation, and bacterial attachment

The feasibility of column bioleaching in the recovery of valuable metals (Ni, V, Mo, and Al) from an uncrushed petroleum refinery spent hydroprocessing catalyst using Acidithiobacillus thiooxidans has been reported. Different operational strategies such as submerged bioleaching in continuous mode, submerged bioleaching in resting period mode, free flow bioleaching in continuous mode, and free flow bioleaching in resting period mode were tested to find out the optimum bioleaching strategy for the recovery of metals from spent hydroprocessing catalyst. Among various operational modifications, submerged bioleaching in continuous mode was considered as the best strategy in which about 82.9% of Ni, 33.4% of Al, and 22.7% of Mo were leached after 315 h of column operation. The maximum yield of V (53.6%) in this column was achieved in 105 h, after which, a rapid decrease in its yield was observed, possibly due to its precipitation. The field emission scanning electron microscopy (FESEM) analysis revealed the presence of V in precipitates. The modified kinetic models showed that the leaching of Al, V and Mo followed the chemical control model, whereas the dissolution of Ni was controlled by diffusion control reaction. The bacterial attachment study with FESEM indicated that the metal toxicity was induced on bacterial cells attached to the sulfur particles. The results of the current study indicate that column bioleaching of spent hydroprocessing catalyst is effective in leaching of Ni and V, whereas leaching of Al and Mo require further treatments.

Sorption and recovery of platinum from simulated spent catalyst solution and refinery wastewater using chemically modified biomass as a novel sorbent

In this study, Lagerstroemia speciosa biomass modified by polyethylenimine (PEI-LS) was developed as a potential biosorbent for sorption and recovery of platinum(II) from platinum bearing waste solutions. Batch experiments were conducted to study the effect of various parameters on the sorption and recovery of platinum(II) using PEI-LS. The equilibrium time for platinum(II) sorption process was found to be 6 h. Both the sorption kinetics and sorption isotherm data fits pseudo second-order kinetic model and Langmuir isotherm, respectively. The maximum sorption capacity of platinum(II) onto PEI-LS at pH 2 for the studied temperature range (25-45 °C) is in the range of 122-154 mg/g. Evaluation of thermodynamic parameters suggests that the platinum(II) sorption is spontaneous and endothermic in nature. The regeneration of PEI-LS can be achieved using acidic thiourea as an eluent for recovery of platinum from the biosorbent. Fourier transform infrared (FT-IR) analysis suggests many functional groups were involved in platinum(II) sorption onto PEI-LS. Both the scanning electron microscope/energy dispersive spectroscopy (SEM/EDS) and X-ray photoelectron spectroscopy (XPS) analysis suggest a successful modification of raw biomass with PEI. The XPS analysis further concludes that platinum(II) sorption is governed by ion-exchange and co-ordination reaction. Finally, the PEI-LS was shown to recover ≥ 90% of platinum from two simulated solutions: the acid-leached spent catalyst solution and refinery wastewater. The biosorbent developed in this study is a low-cost and eco-friendly media that can be effectively used for platinum recovery from industrial wastewater.

Sequential biological process for molybdenum extraction from hydrodesulphurization spent catalyst

Spent catalyst bioleaching with Acidithiobacillus ferrooxidans has been widely studied and low Mo leaching has often been reported. This work describes an enhanced extraction of Mo via a two stage sequential process for the bioleaching of hydrodesulphurization spent catalyst containing Molybdenum, Nickel and, Aluminium. In the first stage, two-step bioleaching was performed using Acidithiobacillus ferrooxidans, and achieved 89.4% Ni, 20.9% Mo and 12.7% Al extraction in 15 days. To increase Mo extraction, the bioleached catalyst was subjected to a second stage bioleaching using Escherichia coli, during which 99% of the remaining Mo was extracted in 25 days. This sequential bioleaching strategy selectively extracted Ni in the first stage and Mo in the second stage, and is a more environmentally friendly alternative to sequential chemical leaching with alkaline reagents for improved Mo extraction. Kinetic modelling to establish the rate determining step in both stages of bioleaching showed that in the first stage, Mo extraction was chemical reaction controlled whereas in the subsequent stage, product layer diffusion model provided the best fit.

Recovery of vanadium from spent catalysts of sulfuric acid plant by using inorganic and organic acids: Laboratory and semi-pilot tests

Catalysts are used extensively in industry to purify and upgrade various feeds and to improve process efficiency. These catalysts lose their activity with time. Spent catalysts from a sulfuric acid plant (main elemental composition: 5.71% V2O5, 1.89% Al2O3, 1.17% Fe2O3 and 61.04% SiO2; and the rest constituting several other oxides in traces/minute quantities) were used as a secondary source for vanadium recovery. Experimental studies were conducted by using three different leaching systems (citric acid with hydrogen peroxide, oxalic acid with hydrogen peroxide and sulfuric acid with hydrogen peroxide). The effects of leaching time, temperature, concentration of reagents and solid/liquid (S/L) ratio were investigated. Under optimum conditions (1:25 S/L ratio, 0.1 M citric acid, 0.1 M hydrogen peroxide, 50°C and 120 min), 95% V was recovered in the presence of hydrogen peroxide in citric acid leaching.

A novel "wastes-treat-wastes" technology: role and potential of spent fluid catalytic cracking catalyst assisted ozonation of petrochemical wastewater

Catalytic ozonation is a promising wastewater treatment technology. However, the high cost of the catalyst hinders its application. A novel "wastes-treat-wastes" technology was developed to reuse spent fluid catalytic cracking catalysts (sFCCc) for the ozonation of petrochemical wastewater in this study. Multivalent vanadium (V(4+) and V(5+)), iron (Fe(2+) and Fe(3+)) and nickel (Ni(2+)) oxides that are distributed on the surface of sFCCc and poisoned FCC catalysts are the catalytic components for ozonation. The sFCCc assisted catalytic ozonation (sFCCc-O) of nitrobenzene indicated that the sFCCc significantly promoted hydroxyl radical mediated oxidation. The degradation rate constant of nitrobenzene in sFCCc-O (0.0794 min(-1) at 298 K) was approximately doubled in comparison with that in single ozonation (0.0362 min(-1) at 298 K). The sFCCc-O of petrochemical wastewater increased chemical oxygen demand removal efficiency by three-fold relative to single ozonation. The number of oxygen-containing (Ox) polar contaminants in the effluent (253) from sFCCc-O treatment decreased to about 70% of the initial wastewater (353). The increased oxygen/carbon atomic ratio and decreased number of Ox polar contaminants indicated a high degree of degradation. The present study showed the role and potential of sFCCc for catalytic ozonation of petrochemical wastewater, particularly in an advantage of the cost-effectiveness through "wastes-treat-wastes".

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

The present study dealt with the whole valorization process of exhaust refinery catalysts, including metal extraction by ferric iron leaching and metal recovery by precipitation with sodium hydroxide. In the leaching operation the effects on metal recovery of the concentration and kind of acid, the concentration of catalyst and iron (III) were determined. The best operating conditions were 0.05 mol L(-1) sulfuric acid, 40 g L(-1) iron (III), 10% catalyst concentration; almost complete extraction of nickel and vanadium, and 50%extraction efficiency of aluminium and less than 20% for molybdenum. Sequential precipitation on the leach liquor showed that it was not possible to separate metals through such an approach and a recovery operation by means of a single-stage precipitation at pH 6.5 would simplify the procedures and give a product with an average content of iron (68%), aluminium (13%), vanadium (11%), nickel (6%) and molybdenum (1%) which would be potentially of interest in the iron alloy market. The environmental sustainability of the process was also assessed by means of life cycle assessment and yielded an estimate that the highest impact was in the category of global warming potential with 0.42 kg carbon dioxide per kg recovered metal.