Recycling and recovery
Spent catalyst recovery
Reclaiming molybdenum, nickel, cobalt, vanadium and platinum group metals from refinery and chemical catalyst.
Spent hydroprocessing and chemical catalyst carries recoverable molybdenum, nickel, cobalt, vanadium and platinum group metals. Recovery is standard practice on most refinery catalyst, and the metal value frequently offsets a substantial part of the handling cost.
Source: 40 CFR 261.4(a)(12) on certain spent catalyst, and Part 266Catalyst types we handle
- Hydrotreating and hydrocracking catalyst carrying molybdenum, nickel and cobalt
- Fluid catalytic cracking catalyst and equilibrium catalyst
- Reforming catalyst carrying platinum and rhenium
- Chemical process catalyst including copper, zinc and palladium systems
- Sulfur recovery and tail gas catalyst
Spent catalyst is frequently pyrophoric when first unloaded. Handling and packaging are planned before the turnaround, not during it.
Plan it before the turnaround
Catalyst changeout happens on a turnaround schedule that is fixed months ahead and expensive to slip. The waste decisions are frequently made last, under time pressure, which is the worst moment to be discovering that a stream has no route.
Characterization, packaging and outlet confirmation belong in turnaround planning alongside everything else. Where that happens the catalyst leaves on schedule and the metal value is captured. Where it does not, drums sit on a pad while the paperwork catches up and the accumulation clock runs.
Common questions
Is spent catalyst always hazardous waste?
Not always. Certain spent hydrorefining catalysts are excluded under 40 CFR 261.4(a)(12) when reclaimed, subject to conditions. Others are hazardous by characteristic or by K listing. It is determined per catalyst and per process.
What about pyrophoric catalyst?
It is handled under inert conditions or after controlled passivation. This is planned before unloading begins, because a pyrophoric stream discovered in a drum on a hot pad is an incident rather than a waste question.
Does the metal value come back to me?
On many catalyst streams, yes, as a credit against the handling cost. The figure depends on metal content, current market price and the refiner's terms, and it is quoted before the work rather than settled afterwards.
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This page summarizes federal requirements and is not legal advice. State programs can be more stringent than the federal baseline. Verify against current federal and state regulations before acting. Last reviewed September 2026.