Recovery of metal values from spent hydrodesulfurization catalysts

Abstract

A process is provided for recovering metal values from spent hydrodesulfurization catalyst, the process comprising forming in a pressure reactor an aqueous slurry of finely divided spent catalyst and sodium carbonate, the spent catalyst containing by weight about 2 to 10% Mo, up to about 12% V (e.g., about 2 to 10%), about 0.5 to 4% Co, up to about 10% Ni (e.g., about 0.5 to 5%), occluded oil, coke, sulfide sulfur and the balance essentially alumina. The amount of sodium carbonate employed is at least sufficient under oxidizing conditions to convert molybdenum and any vanadium present to soluble Na.sub.2 MoO.sub.4 and NaVO.sub.3 and to neutralize SO.sub.3 produced during oxidation, the amount of sodium carbonate being at least that required stoichiometrically. The slurry is heated to a temperature of about 200.degree. C. to 350.degree. C. (e.g., 275.degree. C. to 325.degree. C.) and a pressure of about 800 psig to 2500 psig (e.g., about 1500 psig to 2500 psig) for a time at least sufficient to solubilize the molybdenum and vanadium present, the amount of oxygen employed being over about 1.1 times the stoichiometric amount sufficient to oxidize the metal values and sulfur to the maximum oxidized state, and to oxidize the oil and free carbon to CO.sub.2 and H.sub.2 O. The solubilized Mo and V are thereafter separated from each other.