A preliminary process design and economic assessment of a catalyst rejuvenation process for waste disposal of refinery spent catalysts

Spent hydroprocessing catalysts from refineries have been classified as hazardous solid waste by the United States Environmental Protection Agency (USEPA), refiners must find a viable but economical solution to solve this serious environmental issue. Catalyst rejuvenation is an attractive option for minimizing the environmental problems associated with spent catalysts. In this study, a preliminary design for such a process and the corresponding economic analysis are performed to assess the proposed catalyst rejuvenation process for metal-fouled spent catalysts generated in residue hydroprocessing units. The scenarios used in the economic assessment are based on three options of process synthesis and two operator modes. It is found that the option of rejuvenating medium and lightly fouled spent catalyst produced by the refinery will be the best solution for refiners, both environmentally and economically.     

Heterogeneous water phase catalysis as an environmental application: a review

Catalytic water phase processes as an environmental application is a relatively novel subject with tremendous potential in the near future. This review of 120 references presents the wide scale of heterogeneous water phase applications studied mainly within past five years. Both oxidation and hydrogenation processes are included as well as TiO₂ assisted photocatalysis. According to the references, heterogeneous catalysis is developing rapidly. New bimetallic catalysts and supports with higher surface area have improved catalytic efficiency in both oxidation and hydrogenation processes. It also seems that study on use of some waste materials such as red mud as catalyst is a very progressive field. On the whole, the chemical aspects are pretty well known, but the catalyst durability, and in many cases activity as well, has to be improved.     

Optimisation of scrap automotive tyres recycling into valuable liquid fuels

The recycling of rubber from old tyres by batch hydrogenation has been performed using tubing bomb reactors. Important process variables like temperature, reaction time, initial hydrogen pressure and nature of gas used have been studied. In all the runs the maximum total conversion was achieved. Conversion products are comprised of oils and gases, being the asphaltene yield lower than 1% in all conditions tested. The most valuable conversion products, oils, have been systematically analysed by TLC-FID¹ and the influence of the process variables in oils composition has been assessed. From the obtained results, it can be deduced that the conversion of rubber in oils is a fast thermal process, which is neither affected by initial pressure nor the nature of gas used. But on the other hand, the nature of obtained oils and gases is a function of process variables.