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<p>In industrial sulfuric acid production, vanadium-based catalysts are indispensable, yet their inevitable deactivation generates hazardous spent catalyst waste requiring sustainable management. In this study, we focus on the particular problem of the spent catalysts produced at the Moroccan OCP Group plant at Jorf Lasfar (El Jadida), which contain about 4.40% V<sub>2</sub>O<sub>5</sub>, 0.90% Al<sub>2</sub>O<sub>3</sub>, 1.18% Fe<sub>2</sub>O<sub>3</sub>, and 65.23% SiO<sub>2</sub>, together with some metal oxides in traces. The notably high vanadium content of the materials presents serious ecological and disposal problems, but on the other hand, it yields an important secondary resource. In order to make use of this resource, a sustainable recovery process has been developed and involves leaching with oxalic acid followed by hydrothermal treatment to precipitate vanadium. The effect of the time of hydrothermal treatment on the recovery efficiency was investigated in some detail, and a complete characterization (XRD, XRF, SEM–EDX, Raman, FTIR-ATR, ICP-OES) revealed that the vanadium so recovered was mainly in the form of V<sub>2</sub>O<sub>5</sub> and Fe<sub>0.11</sub>V<sub>2</sub>O<sub>5.16</sub>. The optimum hydrothermal conditions (24 h) resulted in a high recovery of 76 wt.% of V<sub>2</sub>O<sub>5</sub> and a vanadium extraction efficiency of 99.75% from the leachate. These results show an eco-efficient method to valorize vanadium wastes, promoting sustainability and the circular economy.</p>

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Sustainable recovery of vanadium from spent sulfuric acid catalysts using oxalic acid leaching and hydrothermal treatment

  • 期刊论文

  • 发表日期：

    2026年5月17日

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  • Noureddine El Hasbaoui,
  • Abdelouahab El Hadrami,
  • Kamal Essifi,
  • Satu Ojala,
  • Rachid Brahmi

摘要

In industrial sulfuric acid production, vanadium-based catalysts are indispensable, yet their inevitable deactivation generates hazardous spent catalyst waste requiring sustainable management. In this study, we focus on the particular problem of the spent catalysts produced at the Moroccan OCP Group plant at Jorf Lasfar (El Jadida), which contain about 4.40% V2O5, 0.90% Al2O3, 1.18% Fe2O3, and 65.23% SiO2, together with some metal oxides in traces. The notably high vanadium content of the materials presents serious ecological and disposal problems, but on the other hand, it yields an important secondary resource. In order to make use of this resource, a sustainable recovery process has been developed and involves leaching with oxalic acid followed by hydrothermal treatment to precipitate vanadium. The effect of the time of hydrothermal treatment on the recovery efficiency was investigated in some detail, and a complete characterization (XRD, XRF, SEM–EDX, Raman, FTIR-ATR, ICP-OES) revealed that the vanadium so recovered was mainly in the form of V2O5 and Fe0.11V2O5.16. The optimum hydrothermal conditions (24 h) resulted in a high recovery of 76 wt.% of V2O5 and a vanadium extraction efficiency of 99.75% from the leachate. These results show an eco-efficient method to valorize vanadium wastes, promoting sustainability and the circular economy.