Hydroconversion Catalyst Metal Recovery Process
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Solution Overview
Problem
The petroleum industry faces challenges in minimizing metal waste and effectively recovering precious metals from reaction effluents during the production of hydroconversion catalysts, leading to significant metal losses and increased environmental impact.
Innovation Solution
A method involving co-precipitation of Group VIB and Group VIII metal precursors, followed by chemical precipitation, ion exchange, or electro-coagulation to recover metal residuals, reducing metal ions in the effluent stream and recycling them for reuse in the catalyst production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional catalyst production methods are used, then catalysts can be manufactured, but up to 60% of metal feed is wasted and discharged in effluent stream
Solution Approach 1:
The patent implements a metal recovery system that captures metal residuals from the effluent stream through chemical precipitation, ion exchange, or electro-coagulation processes. The recovered metals are then recycled back into the catalyst production process, transforming the conventional discard approach into a recovery-and-recycle system that reduces metal waste by up to 80% while maintaining manufacturing efficiency
Solution Approach 2:
The patent establishes a feedback loop where metal residuals in the effluent are continuously monitored and recovered, then fed back into the catalyst production process. This closed-loop system ensures that metal losses are minimized by constantly returning recovered metals to the production stream, creating a self-sustaining process that reduces waste without complicating manufacturing
2Loss of substance
If metal recovery processes are implemented, then metal waste is minimized and metals are recovered for reuse, but process complexity increases with multiple treatment steps
Solution Approach 1:
The patent applies different treatment methods (chemical precipitation, ion exchange, electro-coagulation) to different portions or stages of the effluent stream based on local requirements. Each method is selected and applied where it is most effective for the specific metal residuals present at that stage, optimizing recovery while managing overall process complexity through targeted local interventions
3Measurement precision
If chemical precipitation is used to recover metals, then metal ions are removed from effluent, but additional chemicals are consumed and more sludge is generated
Solution Approach 1:
The patent recovers the chemicals consumed during precipitation by treating the resulting sludge to extract and recycle the precipitating agents back into the process. This approach reduces net chemical consumption while maintaining high metal ion removal efficiency, as the chemicals are not truly discarded but recovered and reused
Solution Approach 2:
The patent transforms the harmful sludge byproduct of precipitation into a valuable resource by extracting metals and recovered chemicals from it. The sludge that would normally be waste is converted into a source of recoverable materials, turning the harmful effect of chemical consumption into a beneficial recovery opportunity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes metal waste, recovers at least 80% of metal ions, and reduces metal residuals in the effluent to less than 50 ppm, thereby enhancing the sustainability and efficiency of hydroprocessing catalyst production.
Implementation Method 1
co-precipitating at reaction conditions at least one of a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor; isolating the catalyst precursor from the mixture, forming a supernatant
Implementation Method 2
treating the supernatant by any of chemical precipitation, ion exchange, electro-coagulation, and combinations thereof to generate first effluent stream containing less than 50 mole % of at least one of the metal residuals
Implementation Method 3
treating the supernatant by any of chemical precipitation, ion exchange, electro-coagulation, and combinations thereof to generate first effluent stream containing less than 50 mole % of at least one of the metal residuals
Implementation Method 4
treating the supernatant by any of chemical precipitation, ion exchange, electro-coagulation, and combinations thereof to generate first effluent stream containing less than 50 mole % of at least one of the metal residuals
Implementation Method 5
sulfiding the catalyst precursor forming the bulk catalyst
Data Source
AI summary
In a process for forming a bulk hydroprocessing catalyst by sulfiding a catalyst precursor made in a co-precipitation reaction, up to 60% of the metal precursor feeds do not react to form catalyst precursor and end up in the supernatant as metal residuals. In the present disclosure, the metals can be recovered in a chemical precipitation step, wherein the supernatant is mixed with at least one of an acid, a sulfide-containing compound, a base, and combinations thereof to precipitate at least 50% of metal ions in at least one of the metal residuals, wherein the precipitation is carried out at a pre-select pH. The precipitate is isolated and recovered, yielding an effluent stream. The precipitate and/or the effluent stream can be further treated to form at least a metal precursor feed which can be used in the co-precipitation reaction. The process generates an effluent to waste treatment containing less than 50 ppm metals.