Nov-2024

Key actions for precious metal catalysts (ERTC 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 PM 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 PM catalysts.

Key Action Point One: Procurement
Effective lifecycle management requires meticulous attention to every phase involving the handling of PM catalysts right through the final assessment of their PM content. A critical initial step is understanding the quantity of PM present in the fresh catalyst. Companies that conduct thorough sampling and testing at this stage demonstrate foresight. Due to variations in PM loading during catalyst manufacturing, each catalyst bead and, consequently, each drum of catalyst can vary slightly. Manufacturers of products containing PM 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 PM, 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 PM in spent catalysts during reactor changeouts. Accurate tracking of PM 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 PM on their surface, can have fines containing significantly higher concentrations of PM per kilogram compared to the original catalyst beads. For instance, a typical PM 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 PM refiner.
• Further considerations: Upon reaching the PM 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 PM-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 PM 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 PM-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 PM 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 PM 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 PM 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 PM 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 PM. 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 is crucial to recognise that expenses related to transportation, PM refining services, and third-party representation pale in comparison to the inherent value of PM. 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:
• Splitting limit: This defines the maximum acceptable discrepancy between buyer and seller analytical results. If results fall within this limit, the average is calculated for transaction purposes. Exceeding the limit necessitates a control sample sent to a third-party lab for resolution, known as the ‘umpire’. Standard industry practice dictates a splitting limit of 1% relative, but less scrupulous refiners may attempt to raise this to 5% or even 10%, risking substantial financial compromise. A 1% limit mitigates risk and enhances analytical accuracy by demonstrating sample consistency and compelling labs to replicate each other’s findings.
• Lot size limitation: Implementing limits on the monetary value within individual assay lots supports control and risk management. Excessive monetary concentration in a single lot does not improve laboratory accuracy. It is advisable for PM refiners to create multiple smaller-value assay lots (for example, €500,000) rather than fewer larger-value lots to account for standard deviation and repeatability.
• Penalties and hidden charges: Some PM reclaimers include penalties in contract fine print based on powder levels, carbon content, or minute quantities of other elements in spent catalyst shipments. These penalties can exceed €40,000 per instance if clients are unaware of these risks.
To sum up these key action points for safeguarding your profits:
• Contractual details: Understand the distinct terminology in PM reclaim contracts and meticulously review all provisions.
• Third-party oversight: Consider engaging witnesses for reclamation and possibly representation for catalyst manufacturing processes and reactor loading/unloading.
• Third-party laboratory: Comprehend assay exchanges and maintain thorough records to evaluate third-party lab performance. Ideally, only about 10% of exchanges should require umpire involvement.
• Shipping and hazardous classification: While outsourced handlers can aid, ensure experts internally and externally manage liabilities and transport expenses, especially for shipments classified as hazardous.
• Spent catalyst condition: Share condition reports with your engineering team to uncover insights for process enhancements and equipment maintenance.
•PM refiner selection: Conduct rigorous due diligence, ensuring adherence to regulatory, safety, and environmental standards through audits and documentation review.
• Documentation: Maintain comprehensive spreadsheets for each PM catalyst unit, tracking usage, historical recovery, vendor performance, and precise PM location.

In conclusion, ensuring responsible recycling practices are upheld combats unethical behaviour and waste in the PM industry. Comprehensive knowledge of financial priorities, employee education, and establishment of internal best practices for catalyst lifecycle management are crucial. Understand the processes and verification of how materials are sampled and treated. Above all, maintain clear understanding and transparency in business relationships.

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