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Elsevier

Handbook of Spent Hydroprocessing Catalysts

Regeneration, Rejuvenation, Reclamation, Environment and Safety

This handbook serves scientists and researchers interested in any aspect of spent hydroprocessing catalysts. Its aim is to assist in the analysis and assessment of refined catalys… Read more

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Description

This handbook serves scientists and researchers interested in any aspect of spent hydroprocessing catalysts. Its aim is to assist in the analysis and assessment of refined catalyst byproducts and processing options, to determine whether spent catalysts can be processed into productive resources. For non-regenerable spent catalysts, the book takes into consideration both safety and ecological implications of utilizing landfill and other waste options.

Key features

  • Provides comprehensive guidance and assistance to those making decisions on the fate of spent catalysts, radically improving strategic options for refining organisations
  • Offers solutions that maximize procedural, regulatory, safety, and preparedness benefits
  • Contains detailed information on hazardous characteristics of spent and regenerated catalysts with deployment recommendations, and acts as a benchmark document for establishing threshold limits of regulated species as well as for developing procedures for handling spent catalysts to ensure environmental acceptance

Readership

This work will be of interest to academic institutions specializing in petroleum research, petroleum companies, and petroleum research institutes, as well as to catalyst regenerators, catalyst manufacturers, metal reclaiming companies, and governments and agencies involved in regulatory affairs.

Table of contents

1. INTRODUCTION

2. DEVELOPMENT IN PETROLEUM REFINING2.1. Conventional Refineries2.2. Revamped conventional refineries2.3. Advanced Refineries

3. HYDROPROCESSING OF PETROLEUM3.1. Feeds for Hydroprocessing 3.1.1. Light feeds3.1.2. Medium heavy feeds3.1.3. Heavy and extra heavy feeds3.2. Hydroprocessing reactions3.3. Hydroprocessing Catalysts3.3.1. Structure and chemical composition3.3.1.1. Co(Ni)-Mo(W)-S phase3.3.1.2. Brim site model3.3.1.3. Co-Mo-S© phase3.3.1.4. Effect of support3.3.1.5. Physical properties3.3.1.6.Improved hydroprocessing catalysts3.4. Hydroprocessing Reactors and Processes3.4.1. Fixed bed reactor systems3.4.1.1. Unibon process3.4.1.2. ARDS and Hyvahl processes3.4.2. Moving and ebullated bed reactors.3.4.3. Comparison of hydroprocessing reactors

4. CATALYST DEACTIVATION4.1. Deactivation Due to Structural Change of Catalyst4.2. Deactivation by Coke and Nitrogen Bases4.3. Combined Effect of Coke and Metals on Deactivation4.4. Effect of Temperature and Hydrogen Pressure4.5. Effect of Mechanical Properties of Catalyst4.6. Mechanism of Catalyst Deactivation4.6.1. Mechanism of coke formation4.6.1.1. Chemical aspects4.6.1.2. Physical aspects4.6.2. Mechanism of metal deposition4.6.2.1. Deposition of inorganic solids4.6.2.2. Deposits of organometallic origin4.6.2.2.1. Vanadium deposits4.6.2.2.2. Nickel and mixed deposits4.7. Modeling of Deactivation Process

5. ENVIRONMENTAL AND SAFETY ASPECTS OF SPENT HYDROPROCESSING CATALYSTS5.1. Regulatory Affairs5.1.1. Classification of spent hydroprocessing catalysts5.1.2. Transportation of spent catalysts5.1.3. Recycling and disposal of spent catalysts5.1.4. Handling of Spent Catalysts on Refinery Site5.1.5. Cradle-to-grave approach to spent catalyst management5.2. Hazardous Characteristics of Spent Hydroprocessing Catalysts5.2.1. Exposure to air5.2.2. Reactions of air with coke5.2.3. Reactions of air with catalyst5.2.4. Leachability5.3. Pretreatment of Spent Catalysts for Disposal

6. REGENERATION6.1. Regenerability of Spent Hydroprocessing Catalysts6.2. Oxidative Regeneration6.2.1. Mechanism of oxidative regeneration6.2.1.1. Oxidation of coke6.2.1.2. Involvement of metals6.2.2. Kinetics of oxidative regeneration6.2.2.1. Chemically controlled kinetics6.2.2.2. Diffusion controlled kinetics6.2.3. Modeling of oxidative regeneration6.2.4. Characterization of regenerated catalyst6.2.4.1. Surface properties6.2.4.2. Activity of regenerated catalysts6.2.4.3. Chemical structure6.2.5. Safety and environmental aspects of oxidative regeneration6.2.6. Other oxidation agents6.3. Other Regeneration Methods6.3.1. Regeneration in H2O and CO26.3.2. Regeneration with nitrogen oxides6.3.3. Reactivation6.3.4. Regeneration Aided by Radiation Treatment6.3.5. Reductive Regeneration6.3.6. Regeneration by Attrition and Abrasion6.3.7. Resulfiding of Regenerated Catalysts6.4. Industrial Regeneration6.4.1. In-situ regeneration6.4.2. Off-site regeneration6.4.3. Mechanical separation of spent catalysts6.4.4. Commercial regeneration processes6.4.4.1. Porocel-Belt regeneration process6.4.4.2. TRICAT regeneration process6.2.4.3. Eurecat process6.2.4.4. REACT process6.2.4.5. ReFRESH process6.2.4.6. Rotary kilns6.4.5. Comparison of regeneration processes

7. REJUVENATION 7.1. Organic Agents7.1.1. Mechanism of rejuvenation by organic agents7.1.2. Kinetics of rejuvenation7.1.3. Emissions from rejuvenation by organic agents7.1.3.1. Gaseous emissions7.1.3.2. Liquid emissions7.1.3.3. Solid emissions7.1.4. Rejuvenation process design7.1.4.1. De-oiling7.1.4.2. Mechanical separation7.1.4.3. Metals leaching process7.1.4.4. Decoking of leached catalysts7.1.4.5. Other auxiliary processes7.1.4.6. Design basis7.2. Inorganic Agents 7.2.1. Acidic agents7.2.2. Basic agents7.2.3. Environmental and safety aspects7.3. Solvent Extraction7.4. Bio-rejuvenation7.5. Non-Leaching Methods for Contaminant Metals Removal

8. CASCADING8.1. Cascading of Spent Catalysts8.2. Cascading of Regenerated Catalysts8.3. Cascading of Rejuvenated Catalysts

9. NEW CATALYSTS FROM SPENT CATALYSTS9.1. Petroleum Applications9.1.1. Reprocessing9.1.1.1. Procedure and analysis9.1.1.2. Testing of coprocessed catalysts9.1.1.3. Effect of hydrothermal treatment on reprocessed catalysts9.1.2. Other preparation methods9.1.3. Spent catalysts in slurry bed hydrocracking9.2. Catalysts for Non-Petroleum Applications9.3. Gas Treatment Sorbents9.4. Preparation of Useful Materials from Spent Catalysts9.4.1. Utilization in cement industry9.4.2. Waster water treatment9.4.3. Other materials9.4.4. Abrasives and alloys9.4.5. Ceramic materials9.4.6. Synthetic aggregates9.4.7. Bricks production

10. SPENT CATALYSTS FROM DEWAXING OPERATIONS10.1. Conventional Catalysts10.2. Dewaxing catalysts10.2.1. Composition of dewaxing catalysts10.2.2. Deactivation10.2.3. Environmental and safety aspects10.2.4. Regeneration10.2.5. Metal reclamation

11. METAL RECLAMATION FROM SPENT CATALYSTS11.1. Laboratory Studies on Metal Reclamation from Spent Hydroprocessing Catalysts11.1.1. Leaching studies11.1.1.1. Leaching with ammonia and ammonium salts solution11.1.1.2. Leaching with acids11.1.1.3. Inorganic acids11.1.1.4. Organic acids11.1.1.5. Alkali leaching 11.1.1.6. Two-stage leaching11.1.1.7. Bio-leaching11.1.2. Roasting with Alkali Compounds11.1.2.1. Roasting with sodium salts11.1.2.2. Roasting with potassium salts11.1.3. Chlorination11.1.4. Metal recovery by carbothermic treatment11.1.5. Metal recovery using electrolytic cells11.1.6. Metal recovery by applying thermal plasma11.1.7. Summary of laboratory studies11.2. Separation of Metals from Solutions11.3. Commercial Processes11.3.1. Gulf Chemical & Metallurgical Process11.3.2. CRI-MET Process11.3.3. EURECAT Process11.3.4. Taiyo Koko Company Process11.3.5. Full Yield Industry Process11.3.6. Moxba-Metrex Process11.3.7. Quanzhuo Jing-Tai Industry Process11.3.8. Metallurg Vanadium Process11.3.9. German Process11.3.10. NIPPON Catalyst Cycle Process12. MARKETS AND PRICE TRENDS FOR METALS IN SPENT HYDROPROCESSING CATALYSTS12.1. Molybdenum12.2. Tungsten12.3. Nickel12.4. Cobalt12.5. Vanadium12.6. Alumina

13. FUTURE PERSPECTIVES

14. REFERENCES

Product details

About the authors

MM

Meena Marafi

Dr. Marafi received her Ph.D. in Chemical Engineering from Aston University/England. Her areas of specialization include: petroleum refining/processes and catalysis, catalyst deactivation, regeneration, rejuvenation and recycling, crude oil assay, petroleum characterization and catalyst development. Dr. Marafi has over 88 publications, including, 2 books, 25 papers published in refereed journals, 25 papers presented in international/local conferences, and 36 reports (technical reports/final reports/progress reports related to projects carried out). Lead 14 contractual projects in the area of petroleum refining and catalysis.
Affiliations and expertise
Petroleum Refining Department, Petroleum Research and Studies Center, Kuwait Institute for Scientific Research, Safat, Kuwait

AS

Anthony Stanislaus

Dr. Stanislaus has over 30 years of research experience in catalysts and processes related to petroleum refining. His research experience includes: upgrading of petroleum residues by catalytic hydroprocessing, deep desulfurization and aromatics hydrogenation of diesel blending streams (clean fuels production), naphtha catalytic reforming for octane improvement, kinetics of hydrotreating reactions, catalyst deactivation and regeneration, spent catalyst reactivation and utilization, catalyst development, characterization, and performance testing. He has published over 100 scientific papers in International Journals and books.
Affiliations and expertise
Petroleum Refining Department, Petroleum Research and Studies Center, Kuwait Institute for Scientific Research, Safat, Kuwait

EF

Edward Furimsky

Dr. Furimsky has some forty years of research in the conversion of petroleum, coal and natural gas to various commercial products. The studies on upgrading petroleum feeds included hydrodesulfurization, hydrodenitrogenation, hydrodeoxygenation, catalyst deactivation and regeneration. The environmental and safety aspects as well as utilization options for spent refinery catalysts were part of the research as well. Scientific productivity includes two books, several book chapters and a dozen of reviews on various aspects of hydroprocessing catalysis, petroleum refining and utilization of refinery residues. Some 130 articles appeared in the referred scientific journals.
Affiliations and expertise
Research Scientific, IMAF Group, Canada

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