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.

Emission characteristics of benzene series in FCC flue gas

Benzene series are considered as air pollutants in refineries. However, the emissions of benzene series in fluid catalytic cracking (FCC) flue gas are poorly understand. In this work, we conduct stack tests on three typical FCC units. Benzene series, including benzene, toluene, xylene and ethyl benzene, are monitored in the flue gas. It shows that the coking degree of the spent catalysts affect the emissions of benzene series significantly, and there are four kinds of carbon-containing precursors in the spent catalyst. A fixed-bed reactor is used to conduct the regeneration simulation experiments, and the flue gas is monitored by TG-MS and FTIR. The emissions of toluene and ethyl benzene are mainly emitted in the early and middle stage of the reaction (250-650 °C), while the emission of benzene is mainly detected in the middle and late stage of the reaction (450-750 °C). Xylene group is not detected in the stack tests and regeneration experiments. Higher emissions of benzene series are released from the spent catalyst with lower C/H ratio during regeneration process. With the increase of oxygen content, the emissions of benzene series decrease, and the initial emission temperature is advanced. These insights can improve the refinery's awareness and control of benzene series in the future.

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.

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.

A review of the valorization and management of industrial spent catalyst waste in the context of sustainable practice: The case of the State of Kuwait in parallel to European industry

Industrial solid waste management encompasses a vital part of developed and developing countries strategies alike. It manages waste generated from vital industries and governs the hazardous waste generated as a major component of integrated waste management strategies. This article reviews the practices that govern the management approaches utilized in the developed world for industrial spent catalysts. It critically assesses the current situation of waste management within the developing world region focusing on the industrial waste component, in a novel attempt to crucially develop a strategy for a way forward based on best practices and future directions with major European industries. The review also draws parallels with European countries to compare their practices with those of the State of Kuwait, which rely solely on landfilling for the management of its industrial waste. Spent catalysts recovery methods are discussed at length covering conventional methods of valuable metals and chemicals recovery (e.g., hydrometallurgical, solid-liquid and liquid-liquid extraction) as well as biological recovery methods. A major gap exists within regulations that govern the practice of managing industrial waste in Kuwait, where it is essential to start regulating industries that generate spent catalysts in-view of encouraging the establishment of valorization industries for metal and chemical recovery. This will also create a sustainable practice within state borders, and can reduce the environmental impact of landfilling such waste in Kuwait.

Hydrodemetallation and Hydrodesulfurization Spent Catalysts Elemental Analysis: Comparison of Wavelength Dispersive X-ray Fluorescence and Atomic Emission Spectrometries

Petroleum industries continuously consume catalysts on very large scales. The recycling of spent catalysts is thus of major economic and environmental importance and its first step consists of the characterization of the valuable metal content. Wavelength dispersive X-ray fluorescence (WDXRF) analysis is compared with inductively coupled plasma atomic emission spectrometry (ICP-AES) for the analysis of five samples of spent hydrodesulphurization (HDS) and hydrodemetallization (HDM) catalysts. The elements are considered for their economic interest (Co, Ni, Mo, and V) or for the problems that can arise when they are present in the sample in significant quantities (Al, As, P, Fe). First, the systematic comparison of the analysis of known synthetic samples was performed. The originality here is that the samples were first beaded with lithium tetraborate (Li₂B₄O₇) for WDXRF analysis and then dissolved in hot HCl 6M for ICP-AES measurements. With this processing, we were able to clearly identify the origin of analytical problems when they arose. Second, the semi-quantitative protocol of WDXRF is compared with the quantitative procedure. Finally, the analysis of the spent catalysts is presented and the information gained by the systematic comparison of ICP-AES and WDXRF is shared. The interest of the simultaneous determination by the two techniques when such complicated heterogeneous matrices are involved is clearly demonstrated.