Regeneration of spent RFCC catalyst irreversibly deactivated by Ni, Fe, and V contained in heavy oil

Three different regeneration methods to recover the catalytic activity of s pent resid fluid catalytic cracking (RFCC) catalyst were investigated. Carb ochlorination method was the most effective to remove contaminant metals fr om spent equilibrium catalyst (E-cat). However, catalytic activity was not restored due to severe chlorination condition. The attempt to remove Fe, Ni , and V as a volatile corresponding metal carbonyl compound from E-cat was not effective due to low reactivity between contaminant metals and CO. The most effective method to rejuvenate spent E-cat was washing with weak acid after converting metals to a water-soluble form by calcination. Electron pr obe micro analysis (EPMA) for the cross-sectional profile of Ni, Fe, and V of the regenerated catalyst particle showed that three regeneration methods removed Ni, Fe, and V unifomly throughout the catalyst particle. (C) 2001 Elsevier Science B.V. All rights reserved.