Off-Site Regeneration of Hydroprocessing Catalysts

Abstract

This paper describes the basic phenomena occurring during oxidative regeneration of hydroprocessing catalysts, as well as laboratory experiments studying the removal of carbon and sulfur as a function of temperature. In addition, the evolution of Surface Area (SA) and Dynamic Oxygen Chemisorption (DOC) values versus regeneration temperature applied is discussed. DOC is used to evaluate the dispersion of the active metal-sulfide phase. DOC and SA measurements are complementary techniques for quality assurance of the regeneration process. A substantial loss of SA is found above 600°C while DOC values begin to decrease at lower temperatures. As regards combustion of C and S, it was found that carbon is readily eliminated in a single step between 300 and 450°C. The elimination of sulfur starts as low as 150°C and is terminated only at high temperatures (>600°C). The combustion of C and S, however, seems to be limited by an oxygen diffusion effect into the pores of the catalyst. The EURECAT regeneration process is described as well as an example of an industrial regeneration. Finally, the regulation aspects concerning handling and transport of spent hydroprocessing catalyst are discussed. The safety aspects for unregenerated catalysts are covered by ADR and IMDG codes, but new European legislation exists concerning waste transport including spent catalyst transport. This may result in stricter regulations concerning the transport of spent catalyst from refinery to regeneration facilities in the very near future.