SOLUTIONS FOR RE-USE OF SPENT CATALYST FROM RFCC. The 21st Joint GCC-Japan Environment Symposium in Qatar (Feb. 5-6, 2013)

Transcription

1 SOLUTIONS FOR RE-USE OF SPENT CATALYST FROM RFCC The 21st Joint GCC-Japan Environment Symposium in Qatar (Feb. 5-6, 2013)

2 Contents Introduction Beneficial Applications of Spent catalysts and Charcoal Generated by Mina Al-Fahl and Sohar Refineries (SQU Research) Pilot Project in using RFCC spent catalyst as cold mix in concrete Export RFCC spent catalyst to Germany for re-cycling in steel mills Utilization of Plasma Technology (By Mitsubishi)

3 RFCC Spent Catalyst (Ecat)

4 Introduction In past years, the spent catalyst was sent to storage sites or landfills. However, with increasing environmental restrictions and concerns, other waste management techniques should be explored. There are two types of waste catalysts produced in oil refineries in Oman, Spent Catalyst/Charcoal from Mina Al- Fahl Refinery and Zeolite Equilibrium Catalyst (ECat) from Sohar Refinery. Approximately 20 tons per day of Ecat. are generated at the Sohar Refinery and the material produced has essentially a fine powder form. Material is collected in one ton (1000 kg) bags, and stored in local designated storage sites.

5 Introduction Storage Sites

6 Sultan Qaboos University research to reuse Spent catalysts and Charcoal The main objective was to investigate potential uses in three major applications as follows: Results: Use of spent catalyst in cement manufacturing. Use of spent catalyst and charcoal as construction materials in highway and building construction. Use of spent catalyst and charcoal as adsorbent materials in environmental applications. The laboratory-based mechanical and durability tests results show that spent catalyst can be re-used in cement manufacturing, masonry hollow blocks, asphalt paving, concrete and road base and sub-base construction. The concentration of the heavy metals in the above applications of reusing RFCC spent catalyst and leached test are within the environmental limits.

7 Pilot Project in using RFCC spent catalyst as cold mix in concrete Re-use on a small scale was started with the Oman Portuguese Cement Company since January 2011 and it is still continue. The strength test is positive and leached test of heavy metals is within the environmental limits. Around 20% of RFCC spent catalyst quantity that generated in 2012 was reused in Oman Portuguese Cement Company.

8 Export RFCC spent catalyst to Germany for re cycling in steel mills Orpic in cooperation with Grace GmbH & Co.KG, the manufacturer of RFCC catalyst, explored various other options to re-use of the spent catalyst. Reworking process of FCC-Catalysts: Ladle covering powder (covering materials to reach an optimal spread ability and insulation of steel). Production of mineral wool (substitute for bauxite). More than 2,600 tons was exported through Grace GmbH & Co.KG for recycle until now.

9 Utilization of Plasma Technology (By Mitsubishi) What is Plasma? Formed when gas e.g. nitrogen is heated to over 5,000 degrees by electric current. Plasma is an ionised (electrically charged and conductive) gas known as 4th state of matter. Thermal plasma emits intense heat and UV light. Thermal plasma arcs widely used in steel industry. Cracks/reforms all organic matter and melts or vitrifies inorganic matter into an inert rock. WEAKENING OF BONDS K 2000 K HIGHER VIBRATION ENERGY, INCREASE COLLISIONS 3000 K DISSOCIATION 5000 K + IONISATION PLASMA STATE

10 Utilization of Plasma Technology (By Mitsubishi) Solution Tetronics standard vitrification furnace 40 tonnes per day 25 tonnes per day throughput treatment. 15 tonnes per day stockpile backlog elimination. Mixed with lime on a 70% waste, 30% lime ratio Vitrify slag, granulate and re-use as construction material Recover and recycle valuable Nickel content Customer operational waste is treated going forward. Current stockpiled waste is progressively shipped offsite. Environmental requirements are fully met. Recycle objectives met.

11 Utilization of Plasma Technology (By Mitsubishi) End product of Plasma Processed Hazardous Waste