Ultrasonic EDTA Leaching for Spent Catalyst Metal Recovery

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for recovering valuable metals like molybdenum, vanadium, nickel, and cobalt from spent hydroprocessing catalysts are energy-intensive, require multiple steps, and involve hazardous chemicals, leading to inefficient metal extraction and environmental concerns.

Innovation Solution

The process involves ultrasonic agitation of spent catalysts with Ethylene Diamine Tetra Acetic Acid (EDTA) to extract these metals, followed by acid treatment to recover the EDTA for reuse, reducing the number of steps and energy consumption while achieving high metal recovery rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If conventional acid or alkali leaching methods are used to recover metals from spent catalysts, then metal recovery can be achieved, but the process requires multiple steps, increased safety requirements, and results in huge loss of chemicals

Engineering Contradiction:

Improvechemical lossVSAvoidprocess steps

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent extracts and removes the harmful acidic or alkaline environment from the leaching process by using EDTA as a neutral chelating agent. This eliminates the need for harsh chemicals while maintaining effective metal extraction, directly addressing the chemical loss and safety issues of conventional methods

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical parameters of the leaching process by substituting strong acids or bases with EDTA, a weak organic chelating agent. This parameter change transforms the process from one requiring multiple safety-controlled steps to a simpler, single-step procedure with minimal chemical loss

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If spent catalysts are discarded as solid waste, then disposal is simple, but valuable metals are lost and environmental hazards increase

Engineering Contradiction:

Improvemetal recoveryVSAvoiddisposal simplicity

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The patent implements a recovery system that extracts valuable metals (Mo, V, Ni, Co) from what would otherwise be discarded waste catalyst. The EDTA chelating agent selectively binds to these metals, allowing their recovery while the spent catalyst support can be disposed of safely, thus converting waste into valuable resources

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent converts the harmful aspect of spent catalyst disposal into a beneficial metal recovery process. By using EDTA leaching, the previously problematic waste material becomes a source of valuable metals, turning an environmental hazard into an economic opportunity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If ultrasonic agitation with EDTA is used for metal extraction, then metal recovery efficiency increases and EDTA can be recovered for reuse, but additional equipment and process steps are required

Engineering Contradiction:

Improvemetal recovery rateVSAvoidequipment requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies ultrasonic vibration to enhance the leaching process. The mechanical energy from ultrasonic waves creates cavitation effects that accelerate EDTA's chelation with metals, significantly improving recovery rates. This mechanical input replaces or supplements more complex chemical or thermal processes

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent implements a self-sustaining system where EDTA is recovered from the leaching solution and reused in subsequent batches. This self-service approach eliminates the need for continuous EDTA input, reducing operational costs and equipment complexity over time while maintaining high productivity

Inventive Principle:

Principle #25Self-service

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 method achieves greater than 96% recovery of molybdenum, vanadium, and nickel with minimal environmental impact and allows for the easy recycling of the EDTA reagent, making it a more efficient and sustainable process compared to conventional methods.

Implementation Method 1

utilizing the chelating property of Ethylene Diamine Tetra Acetic Acid (EDTA)

Methodology Applied

Scientific EffectChelation: Chemical Bonding

Implementation Method 2

subjecting the fine particles in EDTA to ultrasonic agitation

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS8287618B2Method or process for recovering Mo, V, Ni, Co and Al from spent catalysts using ultrasonic assisted leaching with EDTA

Publication Date: 2012.10.16 KUWAIT INST FOR SCI RES

AI summary

A process for the selective recovery of Mo, V, Ni, Co and Al from spent hydroprocessing catalysts includes the steps of treating the spent catalysts to recovery metals, support as well as chemicals. The process steps include deoiling, decoking, washing, dissolving, complexing agent treatment, acid treatment and solvent extraction. This process uses limited steps than conventional processes by the use of ultrasonic agitation for metal extraction and the presence of a chelating agent particularly Ethylene Diamine Tetra-Acetic Acid (EDTA). The process also discloses the compete recovery of the extracting agent EDTA with high purity for reuse.