Catalysis and Reaction

Catalyst deposition on carbon coated receptors, Esma Ines Achouri

Catalytic Hydroconversion of Slurry Petroleum Residues, Said Samih

SO2 recovery for sulfuric acid production by Phosphogypsum decomposition, Rouzbeh Jafari, Jamal Chouki, Salman Bukhari, and Ahmed Chabouni


poly Sherbrook
Catalyst deposition on carbon coated receptors
Several catalytic reforming processes are used for converting hydrocarbons into syngas. The use of a catalyst is during such reaction, is to allow the reactions to be carried out at reasonable temperatures. However catalyst usually deactivates due to poisoning that is mainly caused by secondary reactions, which could be avoided if the heating is local. In order to determine the efficiency of local heating during reforming test a catalyst should be deposited on the surface of a carbon coated receptor. Several synthesis methods have been tested in order to deposit nickel or spinel NiAl2O4 on the surface of the C-SiO2. The three most efficient methods that provided the best deposition results are: polyol-sonication process, hydrothermal synthesis, and plasma technique.

Catalytic Hydroconversion of Slurry Petroleum Residues

The Slurry hydro-conversion of petroleum residue is a very new process, which operates at extreme conditions. A very high conversion can be obtained, with a high selectivity, including a maximum of liquid products and minimum of coke formation. However, the coke formation is a major problem that is neglected by the kinetic models in the literature. Furthermore, there is a lack of knowledge in the hydrodynamic of the slurry bubble reactor at extreme conditions.

 The main objective of this project is to develop a comprehensive model for an industrial catalytic hydro-conversion process for the petroleum residues.  This includes the flowing specific objectives:

  • Development of a kinetic mechanism for the catalytic hydro-conversion of petroleum residues.
  • Development of a compartment model for an industrial bubbling column reactor.

A simplified compartment model of the industrial bubble column reactor is as follows:

SO2 recovery for sulfuric acid production by Phosphogypsum decomposition

Phosphate and phosphate derivatives industry have a significant influence on the several country’s economies such as the USA, China, and Morocco. Phosphogypsum is a by-product of phosphoric acid production using the wet process. The by-product should be separated from the acid and is disposed.

Sizeable phosphoric acid production results in tons of PG disposal to the environment and causes significant issues since this waste has high acidity, radioactivity, and contains fluorine compounds.

On the other hand, Sulfur is quite expensive, and its price can vary considerably. Thus, recycling PG to liberate sulfur to produce acid sulfuric will reduce operating cost of phosphoric acid plant significantly and prevents environmental pollution by PG disposal. 

PEARL is executing a research and development project in collaboration with CONFIDENTIAL CLIENT for sulfur recovery by phosphogypsum decomposition. The objective is to design and simulate a commercial scale phosphogypsum decomposition process to liberate sulfur in the form of SO2 and recycle this product to produce sulfuric acid in the existing acid plant. Through commercial scale conceptual design and simulation, technical challenges, design uncertainties, and economic drivers to deploy this technology will be identified. To mitigate the risks associated with commercialization, a pilot plant will be designed to address all the uncertainties and evaluate proposed mitigations. Execution of the project will satisfy following milestones:

  • Provide conceptual design of a commercial plant,
  • Define the integration plan of the phosphogypsum decomposition process with the existing sulfuric acid production plant,
  • Identify technological locks and design and operation uncertainty.
  • Determine the proper size (capacity) for the pilot unit to resolve design and operational uncertainties of the commercial-scale unit
  • Provide conceptual engineering design for the pilot unit,
  • Deliver design and engineering documents for fabrication and operation of the pilot facility.
  • Conduct a HAZOP review of the pilot unit.
  • Evaluate the pilot’s CAPEX and OPEX