Refining of Precious Metal

Powder Spent Catalysts

Imprint
Published by:
Evonik Industries AG
Catalysts Business Line
Rodenbacher Chaussee 4
63457 Hanau
Germany
Responsible for the content:
Dr. Jrgen Krauter
juergen.krauter@evonik.com
Concept and design:
United Arts
Agency for Communication and Design
Bahnhofstrae 2
65239 Hochheim
Germany
km@united-arts-web.de
Photography:
Robertino Nikolic
www.robertinonikolic.com

Contents

Accelerating Your Chemistry

Evonik A World Leader in Chemical Catalysts
Global Sites

Introduction
Precious Metal Powder Catalysts

The Precious Metal Cycle

Precious Metal Management and Refining

The Recovery Process

Three Key Steps

04
05

08
09

10
11

12
13

Packaging, Transport and Legislation

14
15

Questionnaire and
Ineractive Calculation Tool

16
17

Evonik Brings Value to Your Company

18
19

Our Services
Brochures available from Catalysts

Accelerating
Your Chemistry

Evonik A World Leader

in Chemical Catalysts

Evonik Industries, formerly known as Degussa, has

been a leader in chemical catalysts for almost 40 years.
Now as before, customers all over the world rely
on Evonik as a competent and trusted partner. Today
Evonik is a fully integrated partner in catalysis, with
all three disciplines homogeneous and heterogeneous catalysis and biocatalysis under a single
roof. This makes Evonik unique, and gives our
customers the flexibility of finding the most costefficient solution for their needs.

With its heterogeneous catalysts for batch, semi-batch

and continuous processes, the Catalysts Business Line
serves the life sciences, fine chemicals, industrial chemicals and polymers markets. Our objective is to work
with you to develop and scale up tailor-made catalysts
that will make your production processes more reliable,
more efficient and more predictable.
In this technology driven business, Evonik continues to
invest in state-of-the-art equipment for development,
testing and production. Evonik is continually broadening
its portfolio of technologies and services to deliver optimised catalysts for your process.

04
05

Evonik is a member of

the European Catalyst Manufacturers Association (ECMA),

the Catalyst Manufacturers Association of Japan (CMAJ),
the Synthetic Organic Chemical Manufacturers Association (SOCMA),
the Drug, Chemical & Associated Technologies Association (DCAT) and
the American Chemistry Council (ACC).

Markets

Life Sciences and

Fine Chemicals

Industrial Chemicals
and Intermediates

Polymers

Products

Precious Metal Powder Catalysts

Activated Base Metal Catalysts
Homogeneous Catalysts
Deloxan Metal Scavengers

Continuous Process Catalysts

Fixed Bed catalysts
Fluid Bed catalysts

Supports for
Ziegler-Natta type catalysts

Batch

Continuous

Processes

Silane donors

Batch / Continuous

06
07

All over the world

and always close to you

Our mission

Our vision

Together we bring catalyst ideas to life,

creating value by our passion and focus.

To be globally recognised as the preferred

partner for major catalyst users, and to
develop and attract talented people for our
international team.

Sales offices
Production sites

Introduction

The wide use

of PMPC is due to ...

Precious Metal
Powder Catalysts

examples of possible
combinations

High activity
High selectivity
Good filterability
Good recyclability

Safe and easy start-up

No precious metal loss
Easy precious metal recovery
Quantitative precious metal recovery

precious metal

support

doping

Pd
Pt
Rh
Ru

C
Al2O3
SiO2
CaCO3

Fe
Pb
Cu
V

08
09

Precious Metal
Powder Catalysts

powdered,
heterogeneous catalysts

catalysts for
slurry phase reactions

Precious Metal Powder Catalysts are heterogeneous

catalysts for slurry type reactions that are carried
out in batch or semi-batch mode. They are very
popular in the fine chemicals and pharmaceutical
industry, though there are applications outside these
industries.
For the overall economics of chemical processes that
work with Precious Metal Powder Catalysts, the
recovery of the precious metal is of vital importance.
This brochure describes the recovery of the precious
metals and the related services we offer. Recovery is
essential to maintain the precious metal loop.

precious metal
mounted on a support

highly dispersed,
stable metal crystallites

Evonik manages the whole precious metal cycle,

which starts with the purchase of precious metal
and management of the precious metal account, and
ends with the coordination of all activities around
recovering the precious metals. Our global network
of metal refiners carries out the recovery and refining
for you. They operate state-of-the-art audited and
ISO-certified metal refineries. However, we keep it
simple. There is a single interface between Evonik
and you, our customer.

The Precious
Metal Cycle
Precious Metal Losses
in the Process
The fresh Precious Metal Powder Catalyst is used in
the catalytic process and recycled (i.e. re-used) where
this is applicable. In the chemical process precious
metal losses may occur which has various reasons:
Losses while handling the powder catalysts
Precious metal leaching in the process
Losses of fine catalyst particles in the filtration step
However, our technical experts are more than happy
to assist you to minimise the precious metal losses.
Treatment of Spent Catalysts
After the final usage of the catalyst, it is filtered off and
collected. The spent catalyst does not only contain the
precious metals, but also other chemicals originating from
the chemical process. These compounds can be solvents,
reactants and any other chemical that was in contact with
the catalyst. The spent catalysts should be contaminated
as little as possible with product and solvents. As a rule
of thumb, the cleaner a spent catalyst is, the lower the
refining costs.
Precious Metal Powder Catalysts need to be washed or
steamed before being packed and shipped to the refinery.
The spent catalyst should not be too wet or contain a
separate water layer. The filter cloths can be shipped in
the same drum as the spent catalyst if the filter cloths can
be burnt and if this is compatible with the refining process
(precious metal sampling after combustion, process 2,
below). If the precious metal content is determined
directly from the spent catalyst (precious metal sampling
before burning), no filter cloths or any other solids apart
from the catalyst are allowed. If the spent catalyst drums
contain filter cloths, it is advisable to use material that is
combustible. Filtration aids based on silica may entrap
precious metals, which lowers the recovery rate.

Refining
the Spent Catalyst
The precious metal cycle starts with the manufacture
of precious metal salt solutions from pure precious
metals. The solutions are used as a raw material in the
manufacture of Precious Metal Powder Catalysts, which
are shipped to you for use in your catalytic processes.
The spent catalysts are shipped to a metal refinery, where
the precious metals are extracted. This process leads
to a complete destruction of the catalyst, so this is not a
regeneration step, in which the material remains intact.
Once the precious metal is recovered this takes several
weeks it is booked to your precious metal weight
account. You own the precious metal weight account and
can close this account at any time. Precious metal is taken
from this account for the production of fresh catalyst.
This completes the precious metal cycle.
There is no recycling process without losses. As described, they can occur in the catalytic process and in the
metal refinery. Typically, the precious metal loss in the
catalytic process lies between 2 and 3 %. Figures above
5 % are considered high. Also, in the refining and
recovery process small losses cannot be avoided. The
precious metal loss depends on the nature of the spent
catalyst, the type of precious metal, and the refining
process. To keep the cycle filled with precious metal and
to compensate the unavoidable losses, small amounts
need to be bought.
Please note, you have to own only approximately 40 %
of the precious metal that is turned over in your process
to keep the cycle running. For example, if you consume
1 tonne of catalyst containing 50 kg of precious metal,
you only have to buy approximately 20 kg precious metal
to maintain the cycle.

10
11

precious metal purchase

precious metal account

precious metal loss

precious metal recovery

catalyst production

catalytic process

substrate

precious metal loss

product

The Recovery Process

1
2
3

Process 1
spent catalysts
combustible

homogenisation
of spent catalyst

sampling

combustion

chemical
desintegration

Process 2
spent catalysts
combustible

combustion

homogenisation
of ash

sampling

chemical
desintegration

Process 3
spent catalysts
not combustible

homogenisation
of spent catalyst

sampling

pyrometallurgical
processing in high
temperature furnace

electrolysis

sampling

The Recovery
Process

precious metal analytics

Refining and recovery is a complex process which

comprises several steps that are briefly described here.
After the spent catalysts have arrived at the metals
refinery, the material is inhomogeneous and needs to
be pre-treated before the actual recovery process can
start. In this pre-treatment the spent catalyst material
is homogenised.

credit to your weight account

12
13

separation
of Pt, Pd, Rh, Ru

precious
metal sponge

precious
metal solution

production of
fresh catalyst

Three Key Steps

1. Homogenisation and sampling
The amount of precious metal contained
in the spent catalyst is determined at the
beginning of the recovery process, not
at the end. This is necessary because later
in the process the precious metal from
different customers can no longer be
distinguished.
In process 1, the spent catalyst is homogenised to slurry or a free flowing powder.
A sample taken from the slurry is analysed,
and the precious metal content determined.
In process 2, the spent catalyst is combusted,
the resulting ash is sieved and the coarse
fraction milled. Subsequently, the ashes are
unified and mixed. A sample is taken from
the final ash and the precious metal content
determined. In process 3, the spent catalyst
is homogenised by sieving, screening,
milling and blending, and an analysis is
made from the original homogenised spent
material.

2. Analysis
The samples are analysed using state-ofthe-art analytical methods. Our customers
can also take a sample of the homogenised
material to check the results independently.
The result of the analytical investigation
is the basis for billing and crediting the
precious metal to the weight account.
The amount of precious metal that is
credited is calculated from the analytical
result multiplied by the recovery rate. The
recovery rate, which takes precious metal
losses in the process into account, typically
varies between 90 and 99 % depending on
the process and the precious metal.

3. Precious metal recovery

The analytical results also determine the
process by which the ash is refined to
provide the highest possible yield. The last
step delivers the precious metals in powder
or sponge form with a purity of 99.95 up to
99.99 %. From the pure precious metals,
precious metal solutions are made, which
are used in the manufacture of Precious
Metal Powder Catalysts. This closes the
precious metal cycle.

Packaging,
Transport and Legislation

Packaging

Spent Precious Metal Powder Catalysts need to be

packed with care. If the spent material is classified as
hazardous goods, the package needs to be approved
by the authorities.

Process 1:
precious metal
sampling before
burning

The spent catalyst must not be packed in small bags.

The spent catalyst should be shipped in a large metal
drum, which must not contain any solids apart from
the spent catalyst (e.g. hand gloves, filter cloths, filter
candles).

Processes 2 & 3:
precious metal
sampling after
burning

We recommend polyethylene bags with 25 kg content.

The bags should be stable so that they cannot break
or leak material in any way during transportation and
handling. The polyethylene bags can be burnt together
with the catalyst. The bags should be packed in drums
for shipping. You can use the drums in which the fresh
catalyst was sent. If you equip the drums with an inner
bag, take care that no losses of valuable material can
occur. Material that contains low amounts of precious
metal (e.g. hand gloves, filter cloths, filter candles)
should be packed separately and the drum labelled
accordingly.

In addition, the spent catalyst shall:

be thoroughly washed and steamed and delivered
moist with water but solid for handling and shall not
contain any excess liquid.
not be self combustible.
be packed and marked according to International
transport laws. The spent catalyst shall be packed
with no additional liquid in 60, 120 or 200 L steel
or plastic UN-approved drums with metallic lid or in
approved pails. Authorisation to use other packaging
must be agreed to in advance of a shipment.
be shipped together with a copy of the completed
questionnaire, Information on Spent Precious Metals
Catalyst, and a Material Safety Data Sheet (msds).
Furthermore send the completed questionnaire
10 days in advance of dispatch if possible, but in
any case before dispatch of shipment.
be separated from all materials that are not spent
carbon catalyst, but would be combustible, for
example, cloths and filters. These materials shall be
cleaned and disposed at the customers site or if
included because of precious metal content, they must
be packed and labelled separately. Additional cost or
any change in conditions involved with the processing
of these special materials will be passed on to the
customer.
be prepaid, packed and insured (DDU, duty unpaid,
incl. Declaration T1).

14
15

Transport
and Legislation

Legislation requires the sender of spent catalysts to

obey national and international transport regulations
and traffic laws for residual materials and waste. It must
be checked, for example, if the residual chemicals in
the spent catalyst need to be classified as dangerous
goods. If necessary, special regulations and permits for
packaging and transport may be required.

Classification as dangerous goods

according to Transport Regulations

Classification according
to European Waste Legislation

When shipped as dangerous goods, the catalyst has to

be packed in approved drums that are not corrosive for
the contents and are suitable for transport and storage.
The shelf life of plastic drums must be good for at least
half a year after arrival. Any receptacle must be no
more than four and one half years old.
Furthermore, all requirements concerning the transport and handling of dangerous goods shall be observed, particularly those for the receptacles, labels
and documentation.
For example, markings shall include: UN-number,
consignor, consignee, gross and net weight, transport
and dangerous goods classification.
Furthermore, the corresponding transport emergency
cards and instructions in writing have to accompany
the shipment.

Although your material has a high value and is sent

for recovery of precious metals, it is considered
waste according to the EU Regulation. Therefore the
classification number according to European Waste
Catalogue (EWC), new (AVV) must be stated in
all shipping documents together with the material
description.
The law says that the shipper of waste is responsible
for the declaration: Based on experience your
material could be classified as follows according to
the European Waste Catalogue (EWC):
160801, spent catalysts containing gold, silver,
rhenium, rhodium, palladium, iridium or platinum,
if no disturbing elements and no dangerous transition
metals or combinations in the sense of the Regulation
91/689/EWC are contained.
160807*, spent catalysts contaminated with
disturbing elements. Here we refer to regulation
91/689/EWC, for example contaminations with
corresponding amounts of organic compounds,
acids, lead, bismuths, etc.

Questionnaire and
Interactive Calculation Tool

Questionnaire

Some metal refineries require a completed questionnaire that describes the spent catalyst
material. This is necessary to guarantee maximum safety for the operators in the metal refinery
plant. Therefore, we recommend sending the questionnaire together with the spent catalyst.

Information on Spent Precious Metals Catalyst

from company / plant:
in case of several lots / catalyst types per shipment, please fill one questionnaire for each lot / type
1. Type of material / name of catalyst:

Shipping weights:
Type and number of packing:
Labelling:
2. Material condition:

gross:
net:

dry powder

kg
kg

sludge

filter cake

spheres/extrudates

3. Material Composition (indications in weight-%, relative to original weight delivered):

base material:
ca
% solvents:
ca
%

moisture:
ca
% organic substances: ca
%
(besides chemical solvents)
classification:

inorganic / non combustible
filteragents: organic / combustible

expected precious metals (Pt, Pd, Ru etc) other elements (Pb, Bi, Zn, F, Sn, Cr, S, P, As, Sb, Hg + combinations

ca
ca
ca

%
%
%

ca
ca
ca

%
%
%

ca
ca
ca

%
%
%

in form of: (e.g. salts, organic compounds, acids)

4. Properties of the material:
4.1 Technical:

4.2 Physiological:

non combustible
harmless

toxic

Flashpoint > 55 C
LD 50

harmfull

effects:

further information:

4.3 Does the Material contain halogenated organic combinations?

irritant

yes

corrosive

no

if yes:
5. Precautions to be observed when handling the material:
protective equipment and / or antidotes:
6. Classification according to transport regulations and dangerous substance- and preparations directives
yes

no

6.2 Dangerous material acc. to dangerous substance- and preparations directive: yes

no

no

6.1 Dangerous goods acc. to transport regulations:

transport classification:

labelling acc. to dangerous material regulations

EU-Material Safety Data Sheet (msds) is available and attached:

yes

7. Classification according to European Waste Regulation: AVV(EWC)-No

OECD-No

We confirm that the above mentioned data are complete and correct
place

date

authorised signature and stamp

as no

dangerous
material

16
17

Interactive
Calculation Tool

On our web site we have installed an

interactive calculation tool. This webbased tool takes the whole precious metal
cycle and the catalyst productivity into
account. Since you can use the actual
figures for precious metal and recovery
prices, interest rates, catalyst productivity
and precious metal loss, this tool gives
you a rather exact idea about the value
catalysts from Evonik create. We would
be happy to assist you in the application
of this model.

www.evonik.com/catalysts

Annual Catalyst demand

kg/a

Calculation
in g and prices in Euro
in troy ounce and prices in US
Amount of precious metal contained therein

kg

Percentage of the annually used amount of precious metal

used to form the precious metal stock (typically 30 %)

Customers precious metal stock

kg*

Precious metal losses

(estimated)

Catalyst price

/kg

Recovery price
(per gram or troy ounce precious metal credited)

/g

Precious metal price

/g

Interest Rate
(typically 2 % - 5 %)

%**

1. Catalyst Costs

2. Recovery Costs

3. Make up for precious metal losses

( balanced by additional purchase)

4. Interest

Total

Costs for minimum stock of precious metal

Amount of product made in catalytic reaction in one year

/a

Catalyst costs per kg product

/kg

Evonik Brings Value

to Your Company

Our Services

Evonik has built an extended service package around precious metal

recovery and precious metal management. Our services help you to optimise
logistics, purchasing and financing of the precious metals you need.

Financing

Precious Metal Purchasing

Transition borrowing
Long-term borrowing
Sell and lease-back
Options
Forwards
Futures

Spot market orders (in most cases)

Fixing orders (London fixing plus location-charges)
Limit orders
Split orders
Options
Forwards

Please note:
securities are necessary,
e.g. a bank guarantee.

Brochures
available from
Catalysts

Activated Base Metal Catalysts

Continuous Process Catalysts

Deloxan

Products and Services

Handling and Safety

Products and Services

ReacToCat

Metal Scavengers

18
19

Services around Recovery

Related Services

Logistics for spent catalysts

Shipping provisions
Packaging
Material constitution
Contaminations
Pick-Up Service
Documentation
Waste classification
Transport classification
Analysis and Settlement
approved variety of analytical methods available
quick assay possible, third party analysis
high yields due to state-of-the-art processes
settlement on due date and credit to weight
account (free of charge)

Precious metal hotline

Market Statistics
Cooperation with precious metal firms with
outstanding reputation
Logistics for precious metal transactions
transfers
swaps
physical shipments
Determination of the precious metal demand
in the precious metal cycle
critical (minimum) demand
future demand

Homogeneous Catalysts

Olefin Polymerisation Catalysts

Precious Metal Powder Catalysts

Products and Services

Products and Services

Products and Services

Handling and Safety
Refining of Spent Catalysts

Europe
Evonik Degussa GmbH
Catalysts Business Line
Rodenbacher Chaussee 4
63457 Hanau
Germany
phone +49-6181-59-8721
fax
+49-6181-59-2699
North America
Evonik Degussa Corporation
379 Interpace Parkway
P.O. Box 677
Parsippany, NJ 07054-0677
USA
phone +1-800-422-8773
fax +1-973-541-8504
China
Evonik Degussa (China) Co. Ltd.
55 Chundong Road
Xinzhuang Industry Park
Shanghai 201108
China
phone +86-21-6119-1461
fax
+86-21-6119-1142
South America
Evonik Degussa Brazil Ltda.
Catalysts Business Line
Alameda Campinas, 579
5th floor
01404-000 So Paulo-SP
Brazil
phone +55-11-3146-4114
fax
+55-11-3146-4199
Australia
Evonik Degussa (China) Co. Ltd.
55 Chundong Road
Xinzhuang Industry Park
Shanghai 201108
China
phone +86-21-6119-1460
fax
+86-21-6119-1142

India
Evonik Degussa India Pvt. Ltd.
Krislon House,
Opp. Marwah Centre,
Saki Vihar Road,
Saki Naka,
Andheri ( E ),
Mumbai 400 072
India
phone +91-22-6723-8800
fax +91-22-6723-8811
Indonesia
PT. Jebsen & Jessen Chemicals
Graha Inti Fauzi, 7th floor
Jl. Buncit Raya No. 22
Jakarta 12510
Indonesia
phone +62-21-2753-7177
fax +62-21-2753-7188/89
Iran
Degussa Iran AG
No. 20 Kish St., Africa Ave.
P.O.Box 15875-3998
Jahan-E-Kudak Crossroad
Tehran
Iran
phone +98-21-8877 5249
fax
+98-21-8879 7815
Japan
Evonik Degussa Japan Co. Ltd.
Catalysts Business Line
Shinjuku Monolith 12th floor
P.O. Box 7016
2-3-1 Nishi Shinjuku
Shinjuku-ku
Tokyo 163-0938
Japan
phone +81-3-5323-7363
fax
+81-3-5323-8789
Korea
Evonik Degussa Korea Ltd.
94, Galsan 1-dong, Bupyeong-gu
403-081 Incheon
Korea
phone +82-32-510-2419
fax
+82-32-505-2510

Evonik Industries AG
Catalysts Business Line
catalysts@evonik.com
www.evonik.com/catalysts
www.evonik.com

Middle East
Evonik Degussa Gulf FZE
P.O. Box 293594 Location:
Phase 6 A - East Block Office 511
Dubai Airport Free Zone
Dubai, UAE
phone +971-4-204-5580
fax
+971-4-204-5581
Russia
OOO Evonik Chimia
Zemljanij Val 58a, Building 2
RF-109028 Moscow
phone +7 095 721-2862
fax
+7 095 721-2852
Singapore
Jebsen & Jessen Chemicals (S) Pte Ltd
2 Corporation Rd. #06-03 (Main Lobby)
Corporation Place
Singapore 61894
Singapore
phone +65-6305-3488
fax +65-6305-3461
Thailand
Jebsen & Jessen Chemicals(T) Ltd.
23/110-117 Sorachai Bldg.,
25-29th floor
Soi Sukhumvit 63 (Ekamai),
Sukhumvit Road
Klongton Nua, Wattana,
Bangkok 10110
Thailand
phone +66-2-787-8752
fax +66-2-787-8777
Taiwan
Degussa Taiwan Ltd.
9th floor, 133, Min Sheng East Rd.
Sec. 3, Taipei, Taiwan,
105 R.O.C.
phone +886-2-2717-1242
fax
+886-2-2717-2106

This information and all further technical advice is based

on our present knowledge and experience. However,
it implies no liability or other legal responsibility on
our part, including with regard to existing third party
intellectual property rights, especially patent rights.
In particular, no warranty, whether express or implied,
or guarantee of product properties in the legal sense
is intended or implied. We reserve the right to make
any changes according to technological progress or
further developments. The customer is not released
from the obligation to conduct careful inspection and
testing of incoming goods. Performance of the product
described herein should be verified by testing, which
should be carried out only by qualified experts in the
sole responsibility of a customer. Reference to trade names
used by other companies is neither a recommendation,
nor does it imply that similar products could not be used.
Copyright 2009 Evonik Industries AG
pmpc refining 0209