Catalyst Sorting via LIBS Detection

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Solution Overview

Problem

Current methods for separating and regenerating hydrotreatment/hydrocracking catalysts from mixed reactors are inefficient, leading to high waste rates and strategic metal losses due to sintering, contamination, mechanical fragility, and mixing of catalysts with different activities, resulting in only 20% regeneration and significant strategic metal losses.

Innovation Solution

A method utilizing Laser-Induced Breakdown Spectroscopy (LIBS) technology to detect and sort catalysts based on compositional differences, allowing for the separation and potential regeneration of specific catalysts from homogeneous mixtures, with a system capable of processing high volumes of catalyst grains quickly and accurately.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If catalysts are unloaded from reactors after service life, then catalyst performance has decreased and they should be shut down and unloaded, but only 20% are regenerated and 80% become waste due to sintering, contamination, and mechanical fragility

Engineering Contradiction:

Improvecatalyst wasteVSAvoidcatalyst regenerability

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The patent applies preliminary action by detecting catalyst composition and sorting catalysts into different batches before regeneration. This pre-sorting based on compositional analysis (using techniques like XRF or LIBS) allows identification of catalysts suitable for regeneration versus those that will fail, enabling selective processing that maximizes regeneration success rates and minimizes waste generation.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If multiple types of catalysts are loaded into the same reactor to optimize overall performance, then reactor efficiency improves, but catalysts become mixed during unloading and cannot be reused as mixtures are considered waste

Engineering Contradiction:

Improvereactor efficiencyVSAvoidcatalyst recyclability

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent applies segmentation by dividing the mixed catalyst stream into distinct compositional batches through detection and sorting. Each batch is then processed separately for regeneration, transforming an otherwise unusable mixture into separable, regenerable components. This segmentation enables recovery of valuable metals from each catalyst type independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies parameter changes by using compositional analysis to identify and sort catalysts based on their chemical composition parameters. By measuring elemental content (e.g., metal percentages, support material composition), the system distinguishes between different catalyst types and directs them to appropriate regeneration pathways, enabling recovery that would be impossible with uniform processing.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If catalysts are sorted by mechanical properties such as grain size, then separation is possible for catalysts with different sizes, but catalysts with the same grain size cannot be separated even if they have different compositions

Engineering Contradiction:

Improvesorting capabilityVSAvoidcompositional differentiation

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical sorting methods with compositional analysis and sorting. Instead of relying on physical properties like grain size that cannot differentiate between chemically distinct catalysts of the same size, the system uses analytical techniques (XRF, LIBS) to detect elemental composition and sort accordingly, achieving differentiation based on chemical rather than physical characteristics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables the efficient separation and potential regeneration of catalysts, increasing the reuse rate beyond current levels, reducing waste and strategic metal losses, and optimizing the recycling process by accurately distinguishing catalysts with varying compositions and activities.

Implementation Method 1

The catalyst grains of said mixture run past an LIBS detection system that detects the wavelength that is characteristic of said constituent element

Methodology Applied

Scientific EffectLaser-Induced Breakdown Spectroscopy (LIBS): Laser Ablation

Data Source

PatentUS10828632B2Method for compositional sorting of catalyst or adsorbent in mixtures of catalysts and/or adsorbents

Publication Date: 2020.11.10 EURECAT SA

AI summary

A method for separation of at least one catalyst or adsorbent from a homogeneous mixture of catalysts or adsorbents, used in a method for treatment of gas or hydrocarbon feedstock, in which the grains of catalysts or adsorbents are separated according to a sorting threshold corresponding to a content of the constituent element that is sought and defined by the user.