A preliminary process design and economic assessment of a catalyst rejuvenation process for waste disposal of refinery spent catalysts

Spent hydroprocessing catalysts from refineries have been classified as hazardous solid waste by the United States Environmental Protection Agency (USEPA), refiners must find a viable but economical solution to solve this serious environmental issue. Catalyst rejuvenation is an attractive option for minimizing the environmental problems associated with spent catalysts. In this study, a preliminary design for such a process and the corresponding economic analysis are performed to assess the proposed catalyst rejuvenation process for metal-fouled spent catalysts generated in residue hydroprocessing units. The scenarios used in the economic assessment are based on three options of process synthesis and two operator modes. It is found that the option of rejuvenating medium and lightly fouled spent catalyst produced by the refinery will be the best solution for refiners, both environmentally and economically.