Vanadium Recovery from Spent Catalyst Remanufacturing Solution
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Solution Overview
Problem
Current methods are inefficient in recovering valuable metals like vanadium and molybdenum from spent desulfurization catalysts, which are environmentally hazardous and economically challenging due to their high sulfur content and rarity.
Innovation Solution
A method involving the addition of organic acid to spent hydrodesulfurization catalysts, followed by the use of extracting agents and diluents to separate molybdenum and vanadium, and subsequent stripping with calcium salts and ammonia water to recover these metals, optimizing pH levels and phase ratios for effective extraction and recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to recover metals from spent catalyst, then the process is simple, but the extraction rate of valuable metals is low
Solution Approach 1:
The patent segments the metal extraction process into distinct stages: first extracting molybdenum at pH 0.3-1.0, then extracting vanadium at pH 3.0-4.0 from the filtrate. This segmentation allows each metal to be extracted under optimized conditions, achieving high extraction rates for both metals while maintaining a manageable multi-step process
Solution Approach 2:
The patent utilizes parameter changes by adjusting pH levels to different ranges for different extraction stages (pH 0.3-1.0 for molybdenum, pH 3.0-4.0 for vanadium). This parameter optimization enables selective extraction of different metals with high efficiency, resolving the contradiction between extraction rate and process complexity
2Object-affected harmful factors
If spent catalyst is treated as hazardous waste, then environmental safety is ensured, but economic value of valuable metals is lost
Solution Approach 1:
The patent converts the hazardous spent catalyst into a valuable resource by recovering precious metals (molybdenum and vanadium) through selective extraction. The process transforms environmental waste into economic value, achieving both environmental protection and resource recovery simultaneously
3Manufacturing precision
If single-stage extraction is used, then the process is simple, but selective separation of molybdenum and vanadium is poor
Solution Approach 1:
The patent divides the extraction process into two sequential stages with different pH conditions: first stage extracts molybdenum at pH 0.3-1.0, second stage extracts vanadium at pH 3.0-4.0. This segmentation achieves excellent selective separation of both metals while keeping the process complexity at a manageable level
Solution Approach 2:
The patent achieves selective separation by changing the pH parameter between extraction stages. The first extraction occurs at acidic pH (0.3-1.0) for molybdenum, then the pH is adjusted to a higher range (3.0-4.0) for vanadium extraction. This parameter change enables precise control over which metal is extracted at each stage
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 high extraction rates of molybdenum and vanadium, enabling their reuse in selective catalytic reduction catalysts, improving economic viability and environmental handling of spent catalysts.
Implementation Method 1
adding an extracting agent and a diluent to the remanufacturing solution to extract molybdenum
Implementation Method 2
extracting vanadium from an extracted filtrate to obtain an organic phase
Implementation Method 3
adding a stripping agent to the organic phase to strip and recover vanadium
Data Source
AI summary
The disclosure describes a method of separating and recovering valuable metals from remanufacturing solution of a spent desulfurization catalyst containing vanadium, and more particularly, to a method of separating and recovering a valuable metal from remanufacturing solution of a spent desulfurization catalyst containing vanadium, which includes: adding organic acid to a spent hydrodesulfurization catalyst after collecting the spent hydrodesulfurization catalyst in order to prepare the remanufacturing solution of the spent hydrodesulfurization catalyst; adding an extracting agent and a diluent to the remanufacturing solution to extract molybdenum and extracting vanadium from an extracted filtrate to obtain an organic phase; and adding a stripping agent to the organic phase to strip and recover vanadium.