Catalysis 2025 Issue

Control points during the lifecycle of precious metal catalysts

Key contractual factors can greatly influence metal value returns for precious metals spent catalysts

Brad Cook Sabin Metal Corporation

M ore and more petroleum and petrochemical oper- ations around the world are using catalysts that include precious metals (PM), which commonly include platinum, palladium, ruthenium, rhodium, gold, and rhenium. When these catalysts have reached the end of their operational lifespan, they must be replaced during a plant or unit turnaround so plant function can be restored to optimal process efficiency and optimum reaction rates. However, when the spent catalysts are forwarded to a PM refiner, many owners miss opportunities to enhance recovered monetary value, not realising best practices to safeguard profitability. The following discussion aims to provide an overview of control points throughout the life- cycle of PM catalysts and bring some clarity to strategies that maximise financial returns and minimise losses. These control points include: • Procurement • Operational considerations • Reclamation • Documentation. Procurement Strong catalyst lifecycle management demands careful attention to every stage involving the handling of PM cat- alysts, all the way through to the final evaluation of their PM content. A crucial first step is accurately assessing the amount of PM in the fresh catalyst. Companies that con- duct thorough sampling and testing at this stage show foresight. Due to variations in PM loading during catalyst production, each catalyst bead, and therefore each drum of catalyst, can differ slightly. Manufacturers of PM-containing products aim to keep these levels at or above agreed-upon minimums. Statistically, about half of all catalyst drums produced will have less than the average amount of PM, while the other half will have more. Since catalyst manufacturers often pro- duce reformer catalysts in large batches weighing millions of kilograms, pinpointing the exact drums received can be a complex task. Another key factor to consider is the moisture content of the catalyst at the time of purchase. The average water content should be clearly specified on the certificate that comes with the catalyst, as this data plays a crucial role in

assessing the value of PM in spent catalysts during reac- tor changeouts. Proper tracking of PM quantities requires thorough record-keeping throughout the catalyst’s entire lifecycle, ensuring detailed oversight from start to finish. Operational considerations Tiny dust particles, often referred to as ‘fines’ in the industry, are constantly being generated throughout the lifecycle of these catalysts. When fresh catalysts are loaded into reac- tors, it is essential to avoid high wind conditions to prevent the loss of this dust. Many catalysts, particularly those based on alumina and coated with PM, can have fines with much higher concentrations of PM by weight when compared to the original catalyst beads. For example, if a catalyst is loaded with 0.25% platinum, losing one kilo of fresh catalyst beads could result in the loss of 2.5 grams of platinum, worth about €75 at current market prices. In contrast, losing a kilogram of fines during the cata - lyst’s lifecycle could result in the loss of 20 grams or more of platinum, equating to €600 or more per kilogram lost. During processing, catalysts collect various impurities like coke, carbon, moisture, trace solvents, or additives designed to extend their lifespan. These impurities can have a significant effect on the final recovery at the PM refiner. When the catalysts arrive at the refiner, tests are conducted to evaluate impurity levels, moisture content, benzene concentrations, and other factors. This information helps determine whether thermal reduc - tion is needed to remove the impurities before accurate sampling can take place. Experienced process engineers use this impurity data to gain insights into past operations. For example, a high carbon content in spent catalysts from a reformer unit could indicate issues such as channelling, offering valuable feedback to improve reactor operation. Reclamation Proper spent catalysts packaging, weighing, and correct classification for international shipment can be complex, especially for those without experience in the process. While many downstream companies choose to fully outsource the changeout procedure, internal oversight remains essential to ensure the complete collection of all PM-bearing materials, secure cargo handling, and accurate

Catalysis 2025