Conversion of Spent Solid Phosphoric Acid Catalyst to Environmentally Friendly Fertilizer

Abstract

Solid phosphoric acid (SPA) catalysts are widely used in the petroleum industry. Despite a high phosphorus content the spent catalyst is generally not reused. Moreover, due to the limited life spans that are achieved industrially, large quantities of spent catalyst requires disposal, often by landfill. SPA can be readily converted to fertilizer, but the presence of carbonaceous deposits on the catalyst presents a potential environmental hazard. This work demonstrates that these deposits are mostly polyaromatic (amorphous carbon) with smaller amounts of oxygenates and aliphatics. Neither the chemical makeup nor the physical structure of the catalyst or the presence of coke precludes it from use as fertilizer. Subsequently, the spent catalyst was milled, neutralized with lime and ammonium hydroxide, and then calcined to yield a phosphate-rich fertilizer. Toxicity characteristic leaching tests of the spent catalyst fertilizer showed low levels of metals and organics, establishing that no harmful compounds are likely to be absorbed into plant life or groundwater. A plant growth study of the spent catalyst fertilizer indicated that it is approximately as effective as superphosphate fertilizer when used in alkaline soil. The spent catalyst fertilizer is environmentally benign and economically efficient.