Post on 19-Jan-2016
1
Hydrothermal Technology for recovery of Molybdenum from
spent Hydro-Treating catalysts. Wilfred van WijkRob van der Meij
December 3, 2014
2
Rob van der Meij• Serial Entrepreneur in
Clean Tech• > 25 years in catalyst, water
and chemical industry• Akzo Nobel, Cap Gemini,
Shell Chemicals• 7 years Start Ups
Catalysts, Biofuels, Water, Separations
• KiOR, fluXXion, BiAqua, Hermes Catalysts, HyVent
• Chemical Engineer TU Delft, NL
Wilfred van Wijk• > 20 years in
Organophosphorus, Specialty monomer, Organics, Chemical by-and waste streams and general chemical industry• CYTEC Industries
Phosphine and derivatives• 5 years providing
chemistry, chemical and technology solutions; HyVent, Gulf Interchem, ICSP.
•Chemist, University of Leiden, NL
December 3, 2014
3
HyVent Technology
Core Technology ⇨ HydroThermal treatment
Testing facilities in The Netherlandsand Germany
December 3, 2014
Processes in the sub- or
super- critical regime of
water
4
HyVent Technology application areas
Synthesis
OxidesFerrites Heavy Oil Upgrading
BitumenVacuum Resid
Removal of metals
Spent refinery catalystsMixed oxides
Destruction
Toxic wastesOrganic/Inorganic mixturesHigh COD
water
December 3, 2014
5
Historical Molybdenum (Mo) pricing
Hydroprocessing Catalyst contain 15-25% MoO3
MoO
3 pr
ice
(USD
/lb)
?
YearDecember 3, 2014
Historical pricing 2.5 $/lb
Spent hydrotreating catalysts are both a hassle and a source of value
for refiners
Co-Mo Ni-Mo
160,000 tpaRemove S from oil
Legal waste disposal
obligation
Hazardous waste
>20% metalsLargely Mo
20 % Carbon and Sulfur
Needs to be removed prior to processing
Metals value 4000 $/ton
Needs to be removed prior to processing
Export Documentation and transport
hassle
Liability risk when done incorrectly
December 3, 2014 6
7
High costs in metal recovery value chain limits return to
refiner
Unload spent catalyst
Special packaging
Roaster for C,S removal
Metal reclaim
> 65% generated in North America, Europe, Middle East
> 65% reclaim capacity in Asia
⇨ Large transport volumes, Export chemical waste
• Large facilities
• Roasting and metal reclaim often not at same site
⇨ Multi-step location, international processing, documentation hassle
Total costs > $ 2500 /ton
December 3, 2014
8
Current metal recovery technologies for Mo and V have
serious limitations• Roasting for Carbon and Sulfur removal
– Environmentally unfriendly– High capital investment, High maintenance
• Pyro metal recovery– Smelting of material in electronic furnaces– yielding Ferro-alloys used in steel industry, no re-use for catalysts– Low recovery value (alloy)– High capital investment, High energy consumption
• Hydrometallurgical metal recovery– Chemical leaching with acid or base materials– Complex processing with many contamination limitations– Environmentally unfriendly waste waters
December 3, 2014
9
HyVent’s Integrated Processing Scheme
• Hydrothermal dissolution ofC, S and metals
• Destruction of organic compounds
• Combination of proven processes from catalyst and battery recycle industry
• Zero Liquid Discharge process• High recovery value for M and V
Hydrothermal processing Metal Recovery
Spent Catalysts
Water
energy
CO2, N2
Metal salts
solids
Integrated Metal Recovery Process
December 3, 2014
10
The HyVent process is environmentally friendly
No waste water or NOX and SOX emissions
feed
grind
mill
mix
HP Pump
HT Reactor
treatment + leaching
depressurize
centrifuge
Solids collection
Mo recovery
Water treatment
Alumina/Ni/Co cake
liquids
Molybdenum salt
Clean water for re-use
Salts for disposal
Pretreatment Reactor Separation Recovery
Additives
Water
Spent Catalyst V- recovery Vanadium salt
December 3, 2014
Solids
Liquids
11
HyVent uses all commercially proven equipment
All stackable, modular container
framed & sized equipment
Tubular Hydrothermal
Reactor system
Slurry of un-regenerated
catalyst prior to
hydrothermal treatment
December 3, 2014
12
HyVent’s process has strong advantages
Current Processes
Large, fixed unitsHigh CAPEXMulti-location process:
- Roasting separate from metal recovery- multi transport, non-local- export
Metal recoverypyrometallugy ⇨ ferro-alloy (low value)hydrometallurgy ⇨ large acqueous waste volumes
Gas emissionsSulfuroxides, CO2, NOx and C-compounds
HyVent Hydrothermal Process
Modular, smallLow CAPEXLocal, single location process
⇨ C & S removal in process ⇨ Local single transport
Mo and V compound as salt solutions ⇨ high value
Zero Liquid Discharge ⇨ recycle process water
December 3, 2014
13
HyVent will build local, customized, modular facilities to eliminate transport
hassle and reduce costs
• Modular, containerized local facility• NO transport, NO documentation hassle• High return value for Mo and V metal recovery• Modular facility with ‘plug and play’ construction set up• Low CAPEX ⇨ 5-6 million USD per plant• ZLD processing, full water recycle, no emissions• High flexibility to adapt to local market
– Mo or Mo and V recovery– Chemical catalyst processing with other metals (Cu, Zn, RE etc.) add on
possible– Noble metal recovery scheme under development
December 3, 2014
Several 1000-4000 tpa facilities can be build around refining
centers in the world 10,300
60,000
30,000
40,000
Asia
AmericasEurope
Global hydro-processing spent catalyst generation (tons/year)
2
3
11
3
22
2
America’s, Europe, export >65 % of spent catalyst to Asia Pacific now
(VN, K, CN, TW)
# Potential number of facilities by region
1
2
2
1
15
Better return to refiner with HyVent:
⇨ avg >700 $/ton over past 15 years !!
Net return difference for refinery HyVent vs competition
(current pricing)
December 3, 2014 Year (+2000)
USD
/ to
n
16
Higher value return to Refinery without hassle
• Recovery of Mo reduces refinery exposure to metal price fluctuations
• Swap recovered Mo with fresh catalyst Mo
• Better value recovery for refinery
• No documentation and transport hassle for refinery
• No export waste liability risk
• Long term guaranteed off-take agreementDecember 3, 2014
17
Closing remarks
The HyVent integrated HydroThermal process for treatment of spent refinery catalyst and recovery of Molybdenum offers an environmentally friendly, economic and flexible processing technology in answer to changing market demand and requirements
Thank you for your attention
December 3, 2014