US 2006/0135631 A1 · Catalyst recover from a slurry

Abstract

Embodiments of the invention relate to processes and apparatus for the washing and recovery of metal-containing catalyst solids in a form suitable for reclamation. More specifically, a catalyst recovery process comprises removing an organic residue with a washing medium from a metal-containing catalyst solids, recovering washed solids, and treating the washed solids under oxidative conditions to form non-reactive solids. The treatment oxidative conditions may be effective to convert the metal(s) into an oxide form and/or may facilitate the removal of remaining organic residue from the washed solids. The treatment of the washed solids may comprise calcination. In some embodiments, the metal-containing catalyst solids may be recovered from a slurry stream, and the process further comprises passing the slurry stream though a separation unit to obtain a catalyst-enriched retentate slurry. In some embodiments, the organic residue comprises a hydrocarbon wax, and the solid catalyst is a hydrocarbon synthesis particulate catalyst.

Claims25

Dependent claims

A process for recovering a solid metal-containing catalyst from a slurry, said process comprising:

a) providing a catalyst slurry feedstream comprising a solid catalyst and wax hydrocarbons, said solid catalyst including a metallic component;
b) optionally, adding a second feedstream to the catalyst slurry feedstream;
c) passing the catalyst slurry feedstream through a solid-liquid separation unit to separate said slurry feedstream into a liquid stream and a retentate stream, both of which exit the solid-liquid separation unit, wherein the retentate stream is enriched in solid catalyst, and has a content in wax hydrocarbons that is less than the catalyst slurry feedstream;
d) contacting the solid catalyst with a washing medium in a manner effective to displace some of the wax hydrocarbons and wash the solid catalyst;
and
e) treating the washed solid catalyst under conditions sufficient to convert the metallic component into a non-reactive form to generate non-reactive solids.

3 more elements

An integrated process for producing hydrocarbons and recovering spent solid catalyst, comprising:

a) contacting a hydrocarbon synthesis solid catalyst with a feedstream comprising carbon monoxide and hydrogen in a reaction zone under conversion promoting conditions to produce one or more hydrocarbons, wherein the hydrocarbon synthesis solid catalyst comprises a metal, and further wherein a deactivation of said solid catalyst takes place over time within said reaction zone to form spent solid catalyst;
b) withdrawing at least a portion of the hydrocarbon synthesis solid catalyst from the reaction zone to provide a slurry feedstream comprising liquid hydrocarbons and solids, wherein the slurry solids comprising at least a portion of the spent solid catalyst;
c) optionally, performing at least one step selected from the group consisting of:
adjusting the hydrocarbon content of said slurry feedstream;
adjusting the hydrocarbon composition of said slurry feedstream;
adjusting the solids content of said slurry feedstream, and combinations thereof;
d) separating the slurry feedstream into a liquid stream and a solids-enriched stream, wherein the liquid stream comprises most of the liquid hydrocarbons, and further wherein the solids-enriched stream comprises spent solid catalyst and remaining hydrocarbons;
e) treating the solids-enriched stream under oxidative conditions sufficient to oxidize the catalyst metal to a non-zero oxidation state and optionally to remove the remaining hydrocarbons in order to generate oxidized metal-containing solids;
and
f) collecting the oxidized metal-containing solids for reclamation.

7 more elements

Dependencies are inferred from the claim text.

Catalyst recover from a slurry

Life of this patent

Catalyst recover from a slurry

Life of this patent

Abstract

Claims25