NARTC 2025
Lifecycle management of precious metal catalysts
Brad Cook Sabin Metal Corp
Critical operations in many petroleum and petrochemical companies rely on catalysts containing precious metals (PMs) such as platinum, palladium, ruthenium, rhodium, gold, and rhenium. When these catalysts reach the end of their useful life and are replaced during plant turnaround, operations typically benefit from improved process effi- ciency and faster reaction rates. However, when the spent catalysts are sent to a pre- cious metal refiner, many plant owners tend to focus primarily on the monetary recovery, often overlooking opportunities to imple- ment best practices and protect long-term profitability. This article aims to highlight key action points throughout the lifecycle of pre- cious metal catalysts, focusing on strategies to maximise financial returns while minimis- ing operational issues. Key Action Point One: Procurement Effective lifecycle management requires meticulous attention to every phase involv- ing the handling of precious metal catalysts right through the final assessment of their precious metal content. A critical initial step is understanding the quantity of pre- cious metals present in the fresh catalyst. Companies that conduct thorough sam- pling and testing at this stage demonstrate foresight. Due to variations in precious metal loading during catalyst manufactur- ing, each catalyst bead and, consequently, each drum of catalyst can vary slightly. Manufacturers of products containing pre- cious metals strive to maintain these lev- els at or above agreed-upon minimums. Considering statistical averages, approxi- mately half of all catalyst drums produced will contain less than the average amount of precious metal, and the other half will contain more. Given that catalyst manufac- turers often produce reformer catalysts in batches weighing millions of kilograms, it becomes challenging to determine the spe- cific drums received. Another critical consideration is the mois- ture content of the catalyst at the time of purchase. The average water content should be clearly indicated on the certificate accompanying the catalyst, as this informa- tion becomes pivotal in evaluating the value of precious metals in spent catalysts dur- ing reactor changeouts. Accurate tracking of precious metal quantities necessitates comprehensive record-keeping throughout the entire lifecycle of the catalyst, ensuring detailed oversight ‘from cradle to grave’.
Control samples can be sent to a third-party lab for resolution if discrepancies are found Recycling prevents waste of precious metals
lations, permits, and logistical challenges involved in shipping precious metal-bearing catalysts, this expertise is essential. • Selecting a PM refiner: The integrity of the chosen PM refiner is paramount for receiving quality service. Ethical compli- ance within the precious metals industry is critical to avoid financial risks and legal complications. Catalyst owners must exer- cise diligence when selecting a PM recycler, as misleading practices such as distorted metal content or unethical behaviours have plagued the industry. Consulting regula- tory bodies and media sources is advised to ensure a thorough investigation and verifi- cation of safety, environmental compliance, and other certifications. • Quality assurance: Properly weighing cat- alyst shipments, conducting accurate sam- pling, and adhering to the highest industry standards for precious metals analysis are indispensable. Opting for the lowest bidder in sampling and assaying processes may lead to inaccurate evaluations and finan- cial losses. Achieving precise assessment of precious metal assets requires skilled per- sonnel, calibrated equipment, and sufficient time for meticulous analysis. • On-site representation: After completing a pre-qualification audit and confirming the capabilities of the chosen refiner, catalyst owners are strongly encouraged to witness the weighing and sampling processes first- hand. Alternatively, reputable third-party representation companies specialised in this field can act as on-site overseers, ensuring accurate data collection, corroborating the PM refiner’s practices, and maintaining cus- tody control of samples throughout the anal- ysis. This rigorous oversight guarantees that all procedures align with intended protocols and yield reliable results. Key Action Point Four: Documentation Industry dynamics often lead to frequent turnover in roles and responsibilities. With the typical lifespan of a precious metal cat- alyst ranging from two to five years, more purchasing agents, procurement manag-
carbon content in spent catalysts from a reformer unit might indicate issues such as channelling, providing valuable feedback to enhance reactor operation knowledge. Key Action Point Three: Reclamation • During turnaround: Properly packaging, weighing, and correctly classifying spent catalysts for international shipment can be challenging, especially for those inex- perienced with such tasks. While many petroleum and petrochemical companies opt to fully outsource the changeout pro- cess, internal oversight remains crucial to ensure the complete collection of all pre- cious metal-containing materials, secure handling of cargo, and accurate hazardous classification. Ultimately, any losses or lia- bilities incurred affect the company’s bot- tom line rather than the contractor’s. • Transport and logistics: Managing the shipment of hundreds of metric tons of spent catalysts containing substantial val- ues in platinum, palladium, and other pre- cious metals is best handled by specialists. Sabin International Logistics Corporation (SILC) excels in arranging transportation from any global location to Sabin’s recovery and refining facilities. Given the complex maze of domestic and international regu-
metals on their surface, can have fines con- taining significantly higher concentrations of precious metals per kilogram compared to the original catalyst beads. For instance, a typical precious metal catalyst loaded at 0.25% platinum means that losing a kilo- gram of fresh catalyst beads could equate to losing 2.5 grams of platinum, valued at approximately €70 in today’s market. Losing a kilogram of fines during the cata- lyst’s lifecycle could potentially mean losing 20 grams or more of platinum, amounting to €500 or more per kilogram lost. • Impurities and more: Throughout pro- cessing, catalysts accumulate various impu- rities, such as coke, carbon, trace solvents, or additives intended to extend their lifes- pan. These impurities significantly impact final recovery at the precious metal refiner. • Further considerations: Upon reaching the precious metal refiner, tests are con- ducted to assess these impurity levels, moisture content, benzene concentrations, and other factors. This data initially informs decisions on whether thermal reduction is necessary to cleanse the catalysts of these impurities before accurate sampling can proceed. Savvy process engineers lev- erage this impurity data to gain insights into past operations. For example, the high
Key Action Point Two: Operational Considerations
• Dust matters: Throughout the lifecycle of these catalysts, fine particles, commonly referred to as ‘fines’ in the industry, are con- tinually formed. When fresh catalysts are loaded into reactors, it is crucial to avoid high wind conditions to prevent dust forma- tion. Many catalysts, especially those based on alumina and impregnated with precious
Electric arc furnaces
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