Title: Vanadium Recovery from Spent V?O? Catalysts in Sulfuric Acid Manufacturing of Uzbekistan
Authors: Mutalibkhonov S.S., Kholikulov D.B., Khojiev Sh.T., Khudoymuratov Sh.J., Musurmankulova A.S.
Volume: 10
Issue: 5
Pages: 47-53
Publication Date: 2026/05/28
Abstract:
Used oxidizing catalysts that have lost their operational properties are removed from the temperature exchange contact tower layers. Used mass is collected in the warehouse of Sulfuric acid workshop of Copper smelter of AMMC JSC Uzbekistan. The average vanadium content in waste catalysts is 5%. Spent vanadium pentoxide (V?O?) catalysts from sulfuric acid manufacturing represent significant secondary resources containing 5-8% vanadium by weight. This study synthesizes Scopus-indexed literature on vanadium recovery methodologies to assess optimal process parameters and environmental implications. Hydrometallurgical leaching using oxalic acid demonstrated superior recovery rates (94.42% in column experiments), while combined acid systems (sulfuric acid/oxalic acid) achieved 95.65% efficiency. Solvent extraction with Cyanex 272 and Aliquat 336 enabled high-purity vanadium recovery (>99%), with precipitation as ammonium metavanadate yielding crystalline products at 87-99.75% purity. Kinetic analysis revealed diffusion-controlled leaching mechanisms with activation energies of 5.90-17.1 kJ/mol. Operating parameters including temperature (50-90°C), pH (1-2), stirring rate (300 rpm), solid-to-liquid ratio (0.1-0.4), and contact time (3-144 hours) significantly influenced recovery efficiency. Environmental assessment indicated bioleaching with Acidithiobacillus thiooxidans achieved 96% vanadium extraction with reduced metal mobility, simultaneously producing silica-rich residues suitable for construction applications. Emerging technologies including electro-oxidation with ultrasound cavitation (94.64% efficiency) and carbonated water leaching (77% efficiency) provide green alternatives to conventional roasting-leaching processes. This comprehensive analysis demonstrates feasible, scalable approaches for sustainable vanadium recovery, addressing resource scarcity while mitigating environmental hazards associated with accumulated spent catalysts.