Insight studies on the deactivation of sulfuric acid regeneration catalyst

The SAR unit is used for regenerating spent sulfuric acid for alkylation reactions. In the SAR unit, the converter employs a potassium and vanadium-based catalyst for conversion of SO2 to SO3. The multiple bed fixed bed reactor is there to ensure that almost entire amount of SO2 is converted to SO3. On observing the generation of large amounts of fines in the reactor catalyst, the spent catalyst and fines are collected for insight studies. The current study enlightens the possible causes of catalyst deactivation and fines generation. Structural changes in potassium/vanadium based catalyst during the oxidation of sulfur dioxide identified as the major cause of catalyst deactivation. Such structural changes and their impact on catalyst property were determined using various physico-chemical characterization methods like crushing strength, Loss on drying (LOD), XRF, XRD, FTIR and XPS analysis. LOD analysis shows the higher moisture and volatile content in spent and fines compared to fresh catalyst. High moisture content in spent catalyst decreases hardness of catalyst resulting in leaching of vanadium salt and carrier degradation due to thermal cycling. Chemical analysis data found to show the active vanadium content in fines is higher compared to spent which indicates vanadium has leached out from fresh catalyst and is deposited on fines. These observations are further correlated with XRD and XPS results. XPS analysis shows the relative distribution of V4+ and V5+ species on the catalyst surface are altered and found very low concentration of V4+ sites on spent catalyst. The XRD analysis demonstrates the leaching of the active component, potassium vanadyl sulfate K(VO2) (SO4)& sdot;3H2O, which then accumulated in the fines fraction. FT-IR and XRD results further shows increase in sulfate accumulation on spent catalyst surface along with phase changes. FTIR analysis of simulated spent catalyst are well correlated with these findings.