Skip to main content

Advertisement

Log in

A Greener Approach to Extract Copper from Fertilizer Industry Spent Catalyst

  • Research Article-Chemical Engineering
  • Published:
Arabian Journal for Science and Engineering Aims and scope Submit manuscript

Abstract

Large quantities of catalysts after their useful life are discarded as waste material from fertilizer industry. Disposal of spent catalyst is a problem as it falls under the category of hazardous industrial waste due to its heavy metals concentration. This investigation applied a novel approach to extract copper from spent low-temperature shift catalyst (CuO–ZnO–Al2O3) using chelation process. Ethylenediaminetetraacetic acid (EDTA) was used as the chelating agent. Optimum parameters to extract 95% copper were found as: EDTA concentration 0.5 M, reaction temperature 100 °C, solid-to-liquid ratio 1:25 (g/ml), particle size 120 µm and reaction time 4 h. A kinetic analysis of the experimental data was done by shrinking core model which revealed the rate-controlling step of the leaching process as product layer diffusion. The activation energy calculated was 10.58 kJ/mol which supports leaching process to be the product layer diffusion controlled. The process adopted is eco-friendly as the EDTA was recovered after the extraction of copper from the spent catalyst and reused again. The recycled EDTA obtained after the extraction was characterized by NMR and SEM. The activity of the recycled EDTA was found to be consistent with the fresh EDTA.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Jadhav, U.U.; Hocheng, H.: A review of recovery of metals from industrial waste. J. Achiev. Mater. Manuf. Eng. 54, 159–167 (2012)

    Google Scholar 

  2. Oza, R.; Patel, S.: Recovery of nickel from spent Ni/Al2O3 catalysts using acid leaching, chelation and ultrasonication. Res. J. Rec. Sci. 1, 434–443 (2012)

    Google Scholar 

  3. Prajapati, R.P.; Sharma, A.; Tiwari, D.R.: Utilization of spent catalyst (solid waste) from the nitrogeneous chemical plant. Orient. J. Chem. 27(3), 1289–1292 (2011)

    Google Scholar 

  4. Smith, B.; Muruganandam, R.J.; Murthy, L.; Shantha, S.: A review of the water gas shift reaction kinetics. Int. J. Chem. React. Eng. 8, 1–34 (2010)

    Google Scholar 

  5. Singh, B.: Treatment of spent catalyst from the nitrogenous fertilizer industry—a review of the available methods of regeneration, recovery and disposal. J. Hazard. Mater. 167(1–3), 24–37 (2009)

    Article  Google Scholar 

  6. Swaroopa, S.; Ghosh, M.K.; Sanjay, K.; Mishra, B.K.: Extraction of Cu and Cr from a spent Cu–Cr catalyst: recovery enhancement through mechanical activation. Hydrometallurgy 136, 8–14 (2013)

    Article  Google Scholar 

  7. Dowden, D.A.; Kemball, C.: Catalysis, vol. 2, p. 1. Specialist Periodical Report of the Chemical Society, London (1978)

    Google Scholar 

  8. Labanowski, J.; Monna, F.; Bermond, A.; Cambier, P.; Fernandez, C.; Lamy, I.; Van Oort, F.: Kinetic extractions to assess mobilization of Zn, Pb, Cu, and Cd in a metal-contaminated soil: EDTA vs. citrate. Environ. Pollut. 152(3), 693–701 (2008)

    Article  Google Scholar 

  9. Goel, S.; Pant, K.K.; Nigam, K.D.P.: Extraction of nickel from spent catalyst using fresh and recovered EDTA. J. Hazard. Mater. 171, 253–261 (2009)

    Article  Google Scholar 

  10. Chauhan, G.; Pant, K.K.; Nigam, K.D.: Metal recovery from hydroprocessing spent catalyst: a green chemical engineering approach. Ind. Eng. Chem. Res. 52(47), 16724–16736 (2013)

    Article  Google Scholar 

  11. Sharma, S.; Dutta, N.N.; Agrawal, G.K.: Optimization of copper extraction from spent LTS catalyst (CuO–ZnO–Al2O3) using chelating agent: Box–Behnken experimental design methodology. Russ. J. Non-Ferrous Met. 58(1), 22–29 (2017)

    Article  Google Scholar 

  12. Deveci, H.; Yazici, E.Y.; Aydin, U.; Yazici, R.; Akcil, A.: Extraction of copper from scrap TV boards by sulphuric acid leaching under oxidising conditions. In: Proceedings of Going Green-Care Innovation Conference, 8–11 Nov. Vienna, Austria (2010)

  13. Tuncuk, A.; Stazi, V.; Akcil, A.; Yazici, E.; Deveci, H.: Aqueous metal recovery techniques from e-scrap: hydrometallurgy in recycling. Min. Eng. 25, 28–37 (2012)

    Article  Google Scholar 

  14. Mohapatra, M.; Nayak, B.; Sanjay, K.; Subbaiah, T.; Mishra, B.K.: Ligand mediated eco-friendly leaching of zinc from spent catalyst in alkaline media. J. Ind. Eng. Chem. 20(4), 2217–2223 (2013)

    Article  Google Scholar 

  15. Kim, C.; Lee, Y.; Ong, S.K.: Factors affecting EDTA extraction of lead from lead contaminated soils. Chemosphere 51, 845–853 (2003)

    Article  Google Scholar 

  16. Banda, R.; Nguyen, T.H.; Sohn, S.H.; Lee, M.S.: Recovery of valuable metals and regeneration of acid from the leaching solution of spent HDS catalysts by solvent extraction. Hydrometallurgy 133, 161–167 (2013)

    Article  Google Scholar 

  17. Mazurek, K.: Recovery of vanadium, potassium and iron from a spent vanadium catalyst by oxalic acid solution leaching, precipitation and ion exchange processes. Hydrometallurgy 134–135, 26–31 (2013)

    Article  Google Scholar 

  18. Parhi, P.K.; Sethy, T.R.; Sarangi, P.C.K.: Selective dissolution of copper from copper-chromium spent catalyst by baking–leaching process. J. Ind. Eng. Chem. 21, 604–609 (2015)

    Article  Google Scholar 

  19. Yagi, S.; Kunii, D.: Studies on combustion of carbon particles in flames and fluidized beds. In: Fifth Symposium (International) on Combustion, Reinhold, New York, pp. 231–244 (1955)

  20. Levenspiel, O.: Chemical Reaction Engineering, 2nd edn, pp. 364–365. Wiley, New York (1972)

    Google Scholar 

  21. Feng, X.; Long, Z.; Cui, D.; Wang, L.; Huang, X.; Zhang, G.: Kinetics of rare earth leaching from roasted ore of bastnaesite with sulfuric acid. Trans. Nonferrous Met. Soc. China 23(3), 849–854 (2013)

    Article  Google Scholar 

  22. Wadsworth, M.E.; Miller, J.D.: Hydrometallurgical processes. In: Sohn, H.Y., Wadsworth, M.E. (eds.) Rate Processes of Extractive Metallurgy, pp. 133–199. Plenum Press, New York (1979)

    Chapter  Google Scholar 

  23. Georgiou, D.; Papangelakis, V.G.: Sulphuric acid pressure leaching of a limonitic laterite: chemistry and kinetics. Hydrometallurgy 49, 23–46 (1998)

    Article  Google Scholar 

  24. Anand, S.; Das, S.C.; Das, R.P.; Jena, P.K.: Leaching of manganese nodules at elevated temperature and pressure in the presence of oxygen. Hydrometallurgy 20(2), 155–167 (1988)

    Article  Google Scholar 

  25. Lozano, L.J.; Juan, D.: Leaching of vanadium from spent sulphuric acid catalysts. Min. Eng. 14(5), 543–546 (2001)

    Article  Google Scholar 

  26. Mulak, W.; Miazga, B.; Szymczycha, A.: Kinetics of nickel leaching from spent catalyst in sulphuric acid solution. Int. J. Min. Process. 77(4), 231–235 (2005)

    Article  Google Scholar 

  27. Abdel, E.A.: Kinetics of sulfuric acid leaching of low-grade zinc silicate ore. Hydrometallurgy 55(3), 247–254 (2000)

    Article  Google Scholar 

  28. Feng, Q.M.; Shao, Y.H.; Ou, L.M.; Zhang, G.F.; Lu, Y.P.: Kinetics of nickel leaching from roasting-dissolving residue of spent catalyst with sulfuric acid. J. Central South Univ. Technol. 16, 0410 (2009)

    Article  Google Scholar 

  29. Chauhan, G.; Pant, K.K.; Nigam, K.D.P.: Extraction of nickel from spent catalyst using biodegradable chelating agent EDDS. Ind. Eng. Chem. Res. 51, 10354–10363 (2012)

    Article  Google Scholar 

Download references

Acknowledgements

Authors are very grateful to National Fertilizer Limited, Vijaipur, Madhya Pradesh, for providing the spent catalyst. Authors also acknowledge Sophisticated Analytical Instrument Facility Kochi, India, to provide assistance in characterization of EDTA.

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Shina Gautam.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sharma, S., Gautam, A. & Gautam, S. A Greener Approach to Extract Copper from Fertilizer Industry Spent Catalyst. Arab J Sci Eng 45, 7529–7538 (2020). https://doi.org/10.1007/s13369-020-04652-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13369-020-04652-x

Keywords

Navigation