Sep-2024

Key actions for precious metal catalysts (RI 2024)

Many petroleum and petrochemical operations utilise catalysts that most commonly include precious metals (PM), such as platinum, palladium, ruthenium, rhodium, gold, and rhenium.

Brad Cook
Sabin Metal Corp

Article Summary

When these catalysts reach the end of their operational lifespan and are replaced during turnaround, plants experience restored process efficiency and accelerated reaction rates. However, once the spent catalysts are forwarded to a precious metal refiner, the focus of many owners shifts solely to the monetary value recovered, often missing opportunities to adopt best practices and safeguard profitability. This article aims to provide an overview of key action points throughout the lifecycle of precious metal catalysts, emphasising strategies to maximise financial returns while minimising operational challenges.

Key Action Point One: Procurement
Effective lifecycle management requires meticulous attention to every phase involving the handling of precious metal catalysts right through the final assessment of their precious metal content. A critical initial step is understanding the quantity of precious metals present in the fresh catalyst. Companies that conduct thorough sampling and testing at this stage demonstrate foresight.

Due to variations in precious metal loading during catalyst manufacturing, each catalyst bead and, consequently, each drum of catalyst can vary slightly. Manufacturers of products containing precious metals strive to maintain these levels at or above agreed-upon minimums. Considering statistical averages, approximately half of all catalyst drums produced will contain less than the average amount of precious metal, and the other half will contain more. Given that catalyst manufacturers often produce reformer catalysts in batches weighing millions of kilograms, it becomes challenging to determine the specific drums received.

Another critical consideration is the moisture content of the catalyst at the time of purchase. The average water content should be clearly indicated on the certificate accompanying the catalyst, as this information becomes pivotal in evaluating the value of precious metals in spent catalysts during reactor changeouts.

Accurate tracking of precious metal quantities necessitates comprehensive record-keeping throughout the entire lifecycle of the catalyst, ensuring detailed oversight ‘from cradle to grave’.

Key Action Point Two: Operational Considerations
• Dust matters: Throughout the lifecycle of these catalysts, fine particles, commonly referred to as ‘fines’ in the industry, are continually formed. When fresh catalysts are loaded into reactors, it is crucial to avoid high wind conditions to prevent dust formation. Many catalysts, especially those based on alumina and impregnated with precious metals on their surface, can have fines containing significantly higher concentrations of precious metals per kilogram compared to the original catalyst beads. For instance, a typical precious metal catalyst loaded at 0.25% platinum means that losing a kilogram of fresh catalyst beads could equate to losing 2.5 grams of platinum, valued at approximately €70 in today’s market. Losing a kilogram of fines during the catalyst’s lifecycle could potentially mean losing 20 grams or more of platinum, amounting to €500 or more per kilogram lost.
• Impurities and more: Throughout processing, catalysts accumulate various impurities, such as coke, carbon, trace solvents, or additives intended to extend their lifespan. These impurities significantly impact final recovery at the precious metal refiner.
• Further considerations: Upon reaching the precious metal refiner, tests are conducted to assess these impurity levels, moisture content, benzene concentrations, and other factors. This data initially informs decisions on whether thermal reduction is necessary to cleanse the catalysts of these impurities before accurate sampling can proceed. Savvy process engineers leverage this impurity data to gain insights into past operations. For example, the high carbon content in spent catalysts from a reformer unit might indicate issues such as channelling, providing valuable feedback to enhance reactor operation knowledge.

Key Action Point Three: Reclamation
• During turnaround: Properly packaging, weighing, and correctly classifying spent catalysts for international shipment can be challenging, especially for those inexperienced with such tasks. While many petroleum and petrochemical companies opt to fully outsource the changeout process, internal oversight remains crucial to ensure the complete collection of all precious metal-containing materials, secure handling of cargo, and accurate hazardous classification. Ultimately, any losses or liabilities incurred affect the company’s bottom line rather than the contractor’s.
• Transport and logistics: Managing the shipment of hundreds of metric tons of spent catalysts containing substantial values in platinum, palladium, and other precious metals is best handled by specialists. Sabin International Logistics Corporation (SILC) excels in arranging transportation from any global location to Sabin’s recovery and refining facilities. Given the complex maze of domestic and international regulations, permits, and logistical challenges involved in shipping precious metal-bearing catalysts, this expertise is essential.
• Selecting a PM refiner: The integrity of the chosen PM refiner is paramount for receiving quality service. Ethical compliance within the precious metals industry is critical to avoid financial risks and legal complications. Catalyst owners must exercise diligence when selecting a PM recycler, as misleading practices such as distorted metal content or unethical behaviours have plagued the industry. Consulting regulatory bodies and media sources is advised to ensure a thorough investigation and verification of safety, environmental compliance, and other certifications.
• Quality assurance: Properly weighing catalyst shipments, conducting accurate sampling, and adhering to the highest industry standards for precious metals analysis are indispensable. Opting for the lowest bidder in sampling and assaying processes may lead to inaccurate evaluations and financial losses. Achieving precise assessment of precious metal assets requires skilled personnel, calibrated equipment, and sufficient time for meticulous analysis.
• On-site representation: After completing a pre-qualification audit and confirming the capabilities of the chosen refiner, catalyst owners are strongly encouraged to witness the weighing and sampling processes firsthand. Alternatively, reputable third-party representation companies specialised in this field can act as on-site overseers, ensuring accurate data collection, corroborating the PM refiner’s practices, and maintaining custody control of samples throughout the analysis. This rigorous oversight guarantees that all procedures align with intended protocols and yield reliable results.

Key Action Point Four: Documentation
Industry dynamics often lead to frequent turnover in roles and responsibilities. With the typical lifespan of a precious metal catalyst ranging from two to five years, more purchasing agents, procurement managers, and process engineers are encountering their first catalyst changeouts annually. This underscores the necessity for your company to establish a formal, in-house programme for managing precious metals. Utilising spreadsheets and databases to preserve historical data from each PM changeout and recovery will provide specialised insights about vendors and their performance. This information is also useful when analysing individual reactor performance and PM losses.
• Understanding contractual nuances: Many companies overlook the technical intricacies of PM recovery contracts, which often contain unique terms and conditions. Misinterpretation of these contractual details can result in significant revenue losses. It’s crucial to recognise that expenses related to transportation, PM refining services, and third-party representation pale in comparison to the inherent value of precious metals. Neglecting to consider contract specifics can prove more costly than the catalyst reclamation itself. Key contractual elements that can significantly impact metal value returns or increase costs include:

This short article originally appeared in the 2024 Refining India Newspaper, which you can VIEW HERE