Petroleum Research Center, Kuwait Institute for Scientific Research, P.O. Box 24885, 13109, Safat, Kuwait.
Environ Sci Pollut Res Int. 2024 Mar;31(11):17339-17353. doi: 10.1007/s11356-024-32236-x. Epub 2024 Feb 10.
Petroleum spent hydroprocessing catalysts are hazardous solid waste, the efficient recycling of which is a serious challenge to refineries. However, information on the economic feasibility of spent catalysts recycling plants is scarce, which is critical for environmental authorities and decision-makers. In this work, an innovative recycling scheme targeting hydrometallurgical recovery of base metals (Ni, Mo, and V) and transforming low-value Al residue into a high-value boehmite (γ-AlOOH) as the key product was considered an efficient way to beneficiate the hazardous spent hydroprocessing catalysts. A preliminary techno-economic evaluation of such a recycling scheme was performed to assess the feasibility of the proposed recycling scheme. The recovery cost (valuable metals and boehmite) and potential revenue were estimated to study the economics of the process. The preliminary results have suggested that the recycling scheme is economically feasible with a high internal rate of return (IRR) of 12.3%, a net present value of 38.6 million USD, and a short payback period of 8.7 years. Furthermore, a sensitivity analysis (± 10%) conducted on key parameters showed that the selling prices of the finished products and the cost of chemicals were the most important factors affecting plant economics. Overall, the recycling scheme was sustainable and avoided landfilling of spent catalysts as the residue can be beneficiated into a high-value product. The results from the economic feasibility study are likely to assist the stakeholders and decision-makers in making investment and policy decisions for the valorization of spent hydroprocessing catalysts.
废石油加氢处理催化剂是危险的固体废物，高效回收这些废物是炼油厂面临的严峻挑战。然而，关于废催化剂回收工厂的经济可行性的信息却很少，这对于环境管理部门和决策者来说至关重要。在这项工作中，考虑了一种创新的回收方案，该方案旨在通过湿法冶金回收基础金属（Ni、Mo 和 V），并将低价值的铝残渣转化为高价值的拟薄水铝石（γ-AlOOH）作为关键产品，这是一种有效利用危险废加氢处理催化剂的方法。对这种回收方案进行了初步的技术经济评估，以评估所提出的回收方案的可行性。估计了回收成本（有价金属和拟薄水铝石）和潜在收益，以研究该过程的经济性。初步结果表明，该回收方案在经济上是可行的，内部收益率（IRR）为 12.3%，净现值为 3860 万美元，投资回收期为 8.7 年。此外，对关键参数进行了 ±10%的敏感性分析，结果表明，成品的销售价格和化学品的成本是影响工厂经济的最重要因素。总的来说，该回收方案是可持续的，可以避免废催化剂的填埋，因为残渣可以被提炼成高价值的产品。经济可行性研究的结果可能有助于利益相关者和决策者做出投资和政策决策，以实现废加氢处理催化剂的增值。
