Spent Desulfurization Catalyst Remanufacturing Without Leaching Loss
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Solution Overview
Problem
Existing methods for regenerating spent catalysts for heavy oil desulfurization either fail to maintain desulfurization performance over time or incur high costs due to the loss of catalytically active ingredients and require additional processes like leaching, washing, and drying.
Innovation Solution
A method involving low-temperature heat treatment, dry mixing of a spinel-structured metal oxide, a solid polycarboxylic acid, and a catalytically active material precursor, followed by calcination, to restore the spent catalyst's performance without leaching or drying processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat treatment is performed to remove carbonized material and sulfur, then desulfurization performance is temporarily restored, but vanadium components remain deposited and block catalyst micropores, preventing long-term performance maintenance
Solution Approach 1:
The patent extracts and removes vanadium components from the spent catalyst surface using a selective leaching solution (e.g., ammonium oxalate or EDTA solution) at controlled temperatures (50-100°C). This extraction process specifically targets vanadium deposits that block micropores while preserving the catalyst structure and active ingredients, enabling long-term restoration of desulfurization performance
Solution Approach 2:
The patent changes the temperature parameter to low ranges (50-100°C) during the leaching process, which allows selective removal of vanadium components without causing sintering or damage to the catalyst support structure. This parameter control ensures that the micropore structure remains intact and accessible for long-term catalytic activity
2Reliability
If solvent washing and heat treatment are performed to remove vanadium, then vanadium is leached out, but active ingredients (molybdenum and nickel) are also lost, reducing catalytic activity
Solution Approach 1:
The patent applies local quality by using selective leaching agents (ammonium oxalate or EDTA) that have specific affinity for vanadium components at the catalyst surface. The leaching solution is formulated to target vanadium deposits locally without affecting the bulk catalyst structure or embedded active ingredients like molybdenum and nickel, thus achieving selective removal
Solution Approach 2:
The patent controls the leaching temperature parameter within 50-100°C, which is sufficient to dissolve vanadium components but too low to cause significant loss of active ingredients. The solution composition and contact time are also optimized to achieve selective extraction of vanadium while preserving catalytically active materials
3Reliability
If leaching, washing, and drying processes are used to regenerate catalyst, then vanadium is removed, but processing complexity and costs increase significantly
Solution Approach 1:
The patent merges multiple traditional regeneration steps (leaching, washing, drying) into a single integrated low-temperature leaching process. By using a carefully formulated leaching solution that can be directly applied and then simply filtered or decanted, the complex multi-step process is simplified while maintaining effective vanadium removal and catalyst reusability
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
The remanufactured catalyst achieves desulfurization performance and specific surface area equivalent to fresh catalysts, minimizing active ingredient loss and reducing environmental and economic burdens.
Implementation Method 1
heat treatment removes only the deposited carbonized material and sulfur components through oxidation
Implementation Method 2
performing calcination of the resulting mixture obtained by the dry mixing
Data Source
AI summary
Proposed is a method of remanufacturing a spent catalyst for heavy oil desulfurization. More particularly, proposed is a method of remanufacturing a spent catalyst for heavy oil desulfurization, in which the spent catalyst can be used as a substitute for a fresh catalyst, have economic feasibility, and reduce the environmental burden by reusing a spent catalyst that is to be discarded or buried.