Hydroconversion Catalyst Metal Recovery via Electro-Coagulation
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Solution Overview
Problem
The petroleum industry faces challenges in minimizing metal waste and effectively recovering precious metals from effluents during the production of hydroconversion catalysts, leading to significant metal losses and increased waste treatment burdens.
Innovation Solution
A method involving co-precipitation of Group VIB and Promoter metal precursors, followed by chemical precipitation, ion exchange, or electro-coagulation to recover metal residuals, reducing metal ions in effluents to less than 50 mole % and recycling at least 80 mole % of metal ions for reuse in catalyst production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional hydroconversion catalyst production methods are used, then catalysts are formed, but significant metal waste (up to 60% of metal feed) is discharged in effluent streams
Solution Approach 1:
The patent implements recovery of metal residuals from effluent streams through chemical precipitation, ion exchange, or electro-coagulation processes. At least 80 mole % of metal ions are recovered and recycled back to the co-precipitation step, transforming waste into reusable feedstock and reducing metal loss to less than 50 mole % in discharged effluent
Solution Approach 2:
The patent establishes a feedback loop where effluent streams are treated to recover metal residuals, which are then fed back into the catalyst production process. This closed-loop system continuously recycles valuable metals, minimizing waste discharge while maintaining catalyst production productivity
2Object-affected harmful factors
If metal residuals are discharged in effluent streams, then waste treatment processes are overwhelmed, but implementing recovery processes increases process complexity
Solution Approach 1:
The patent applies different treatment parameters (chemical precipitation agents, ion exchange resins, electro-coagulation conditions) to selectively recover metal residuals from effluent streams. By adjusting these parameters, the process effectively reduces environmental impact while managing complexity through established chemical engineering techniques
Solution Approach 2:
The patent introduces intermediary substances and processes (precipitants, ion exchange resins, coagulants) to facilitate metal recovery from effluent streams. These intermediaries enable selective metal extraction and concentration, reducing environmental impact while maintaining manageable process complexity through well-understood chemical mechanisms
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 significantly reduces metal waste, enhances the recovery of precious metals, and minimizes environmental impact by recycling valuable materials, thereby optimizing the hydroprocessing catalyst production process.
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
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
Implementation Method 4
treating the supernatant by any of chemical precipitation, ion exchange, electro-coagulation, and combinations thereof
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. In the present disclosure, the metals can be recovered in an electro-coagulation reactor, wherein portion of the metal residuals in the supernatant reacts with the electrodes to form a slurry containing insoluble metal compounds. The insoluble metal compounds are isolated and recovered, forming an effluent stream. The insoluble metal compounds 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.