Process for separating and recovering base metals from used hydroprocessing catalyst

Abstract

A method is disclosed for separating and recovering base metals from a used hydroprocessing catalyst originating from Group VIB and Group VIII metals and containing at least a Group VB metal. In one embodiment, the method comprises the steps of: contacting the used catalyst with an ammonia leaching solution under conditions sufficient to dissolve the group VIB metal and the Group VIII metal into the leaching solution; forming a leached slurry containing at least a group VIB metal complex and at least a group VIII metal complex, ammonium sulfate and a solid residue containing at least a Group VB metal complex and coke; separating and removing from the leached slurry the solid residue and coke; precipitating from the remaining solution at least a portion of the Group VIB metal complex and at least a portion of the Group VIII metal complex by controlling the pH to form a liquid material substantially free of Group VB, Group VIB and Group VIII metals and another solid material comprising substantially Group VIB and Group VIII metal complexes. Said solid material is further processed by dissolution, means of separation, further means of precipitation and oxidative dissolution to produce, separately, a Group VIB metal product solution, a Group VIII metal product solution and a purified ammonium sulfate product solution.