硅酸盐学报

废旧钒钛基催化剂回收和高值化利用研究进展

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秦玉 ¹ , 孟令钦 ² , 刘鹏飞 ¹^,² , 郝利炜 ¹ , 崔素萍 ² , 王亚丽 ²

硅酸盐学报 | 综合评述 2025,53(5): 1282-1297

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硅酸盐学报 |综合评述 2025 , 53 (5) : 1282 -1297

废旧钒钛基催化剂回收和高值化利用研究进展

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秦玉¹, 孟令钦², 刘鹏飞¹^,², 郝利炜¹, 崔素萍², 王亚丽²

作者信息

^1．北京建筑材料科学研究总院有限公司，北京 100041

^2．北京工业大学材料科学与工程学院，北京 100124

通讯作者:

崔素萍（1964—），女，博士，教授；

郝利炜（1980—），女，硕士，教授级高工。

作者简介:

秦玉（1986—），女，博士，高级工程师。

Research Progress in the Recovery and High-Value Utilization of Spent Vanadium-Titanium Based Catalysts

Yu QIN¹, Lingqin MENG², Pengfei LIU¹^,², Liwei HAO¹, Suping CUI², Yali WANG²

Affiliations

^1.Beijing Building Materials Academy of Sciences Research, Beijing 100041, China

^2.Materials Science and Engineering, Beijing University of Technology, Beijing 100124, China

Corresponding Author:

CUI Suping (1964-), female, Ph.D., Professor. E-mail: cuisuping@bjut.edu.cn;

HAO Liwei (1980-), female, Master, Professorate Senior Engineer. haoliwei@bbma.com.cn

QIN Yu (1986-), female, Ph.D., Senior Engineer. E-mail: qinyu@bbma.com.cn

出版时间: 2025-05-20 doi: 10.14062/j.issn.0454-5648.20240766

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摘要

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在工业脱硝领域，选择性催化还原技术（SCR）因其高效性而备受青睐。然而，SCR催化剂在使用过程中不可避免地逐渐失去活性，且难以通过常规手段再生，导致大量废旧催化剂的产生。这些废旧催化剂含有V、W、Ti等有价组分，对其有效回收可以实现资源循环利用。本文重点介绍了目前商用钒钛基催化剂的失活机制和回收利用途径。详细总结和比较了湿法和火法两种主要回收方法，并介绍了回收工艺涉及的反应机理和各自的优缺点。针对现有回收方法在全面回收所有元素方面的不足，系统梳理了多种工艺的协同处理方式，指出当前研究的焦点应当集中在如何在降低成本、简化操作流程的基础上，进一步提升回收效率。同时，对于回收过程中有价值组分的高值化应用，也提出了进一步研究的必要性。本文旨在为未来废旧催化剂的回收利用提供参考，这对资源回收利用和绿色低碳发展至关重要。

关键词

选择性催化还原 / 废旧钒钛基催化剂 / 失活 / 回收 / 高值化利用

Abstract

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In the field of industrial denitration, Selective Catalytic Reduction (SCR) technology is highly favored for its efficiency. However, SCR catalysts inevitably lose activity over time and are difficult to regenerate through conventional means, resulting in a significant amount of spent catalysts. These spent catalysts contain valuable components such as vanadium (V), tungsten (W), and titanium (Ti), and their effective recovery can enable resource recycling.

This article focuses on the deactivation mechanisms and recycling pathways of commercial vanadium-titanium-based catalysts currently in use. It provides a detailed summary and comparison of the two main recycling methods: hydrometallurgical and pyrometallurgical processes, and discusses the reaction mechanisms involved and the advantages and disadvantages of each. Faced with the challenges of full element recovery in typical methods, this article collates cooperative treatment recycling processes, finding that current work needs to focus on reducing process costs and simplifying procedures while further improving recovery rates. Additionally, the high-value utilization of valuable components is also worthy of in-depth research. This article aims to provide a reference for the future recycling and utilization of spent catalysts, which is crucial for resource recovery and green low-carbon development.

Summary and prospects

Selective Catalytic Reduction (SCR) technology, due to its high efficiency and applicability, has become a core technology for NO_x emission reduction in industries such as steel, cement, and glass. As these industries increasingly rely on SCR technology, the recycling and high-value utilization of spent catalysts have become an urgent issue that needs to be addressed. When spent catalysts are difficult to regenerate, the recovery of valuable components becomes the preferred option.

Thermal treatment methods dominate the recycling process due to their high extraction rates but also bring about issues of high energy consumption and environmental pollution. In contrast, hydrometallurgical processes are favored for their simplicity, low cost, and high single-metal extraction rates, yet their development is limited by the low extraction rates of leaching agents for multiple valuable elements and the leaching of many impurities. Therefore, the integration of multiple processes and the development of high-value-added products represent the future direction for SCR catalyst recycling.

In the recycling process of SCR catalysts, the key lies in the efficient extraction of vanadium (V), tungsten (W), and titanium (Ti) while reducing energy consumption and environmental harm. Both acid and alkali methods can effectively recover over 90% of V, but given the toxicity of V, the use of a reducing acid leaching method is recommended to prioritize vanadium extraction, facilitating the preparation of high-purity V₂O₅. The recovery of W and Ti is more challenging, especially for W, whose leaching rate is limited by the choice and concentration of solvents, with low-concentration alkali leaching rates typically around 70%. Ti is only soluble in concentrated alkali solutions, and due to the high proportion of titanium in spent catalysts, its extraction would consume a large amount of reagents, leading to high costs. Thus, the most reasonable method is to use alkali to leach W while controlling the alkali concentration to retain as much Ti as possible in the residue. The alkaline leachate contains high levels of silicon and aluminum impurities, which need to be purified before the recovery of products. Additionally, the presence of heavy metals in spent catalysts requires targeted adjustments to the recycling process to enhance recovery rates and purity.

Currently, research on the recycling and utilization of spent vanadium-titanium catalysts focuses on the impact of operating conditions and reaction mechanisms on recovery rates, with insufficient evaluation of energy consumption and environmental impacts during the recycling process. Future studies could employ life cycle assessment and material flow analysis to evaluate the environmental impacts and resource efficiency of spent catalyst recycling. Moreover, the development of new and efficient leaching agents, optimization of thermal and hydrometallurgical process conditions, and exploration of high-value utilization pathways for spent catalysts, such as the preparation of new materials or as raw materials for other industrial processes, will be key to advancing SCR catalyst recycling technology.

Key words

selective catalytic reduction / waste vanadium titanium based catalysts / inactivation / recycling / high value utilization

引用本文

秦玉, 孟令钦, 刘鹏飞, 郝利炜, 崔素萍, 王亚丽. 废旧钒钛基催化剂回收和高值化利用研究进展. 硅酸盐学报, 2025 , 53 (5) : 1282 -1297 . DOI: 10.14062/j.issn.0454-5648.20240766

Yu QIN, Lingqin MENG, Pengfei LIU, Liwei HAO, Suping CUI, Yali WANG. Research Progress in the Recovery and High-Value Utilization of Spent Vanadium-Titanium Based Catalysts[J]. Journal of the Chinese Ceramic Society, 2025 , 53 (5) : 1282 -1297 . DOI: 10.14062/j.issn.0454-5648.20240766

基金

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国家自然科学基金(52072009)

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2025年第53卷第5期

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文章信息

doi: 10.14062/j.issn.0454-5648.20240766

接收时间：2024-12-02
首发时间：2026-10-22
出版时间：2025-05-20

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出版历史

收稿日期：2024-12-02
修回日期：2024-12-26

基金

国家自然科学基金(52072009)

作者信息

^1．北京建筑材料科学研究总院有限公司，北京 100041

^2．北京工业大学材料科学与工程学院，北京 100124

通讯作者:

崔素萍（1964—），女，博士，教授；

郝利炜（1980—），女，硕士，教授级高工。

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https://castjournals.cast.org.cn/joweb/gsyxb/CN/10.14062/j.issn.0454-5648.20240766

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2种不同金属材料的力学参数

科 Family	属数 Number of genus	种数 Number of species	占总种数比例 Percentage of total species (%)	属 Genus	种数 Number of species	占总种数比例 Percentage of total species (%)
鹅膏菌科Amanitaceae	2	11	5.26	鹅膏菌属 Amanita	10	4.78
小菇科 Mycenaceae	2	12	5.74	丝盖伞属 Inocybe	5	2.39
多孔菌科 Polyporaceae	8	14	6.70	蜡蘑属 Laccaria	5	2.39
红菇科 Russulaceae	3	23	11.00	小皮伞属 Marasmius	6	2.87
				小菇属 Mycena	11	5.26
				光柄菇属 Pluteus	5	2.39
				红菇属 Russula	17	8.13
				栓菌属 Trametes	5	2.39

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