Resource-saving technology for processing of spent vanadium catalysts with vanadium pentoxide production and integrated utilization of secondary products

The objective of this study is to develop a resource-saving technology for processing spent vanadium catalysts (SVCs) aimed at reducing technogenic load and establishing a closed-loop production cycle.The methodology involves acidic leaching of vanadium using sulfuric acid (2-4 M, 80 °C), followed by a two-stage ammonification of the filtrate and thermal decomposition of the resulting precipitate.The results demonstrate high vanadium recovery rates (up to 97-98%) and the production of high-purity vanadium pentoxide (98.2%).By-products include sulfate-ammonium fertilizers (8-10% N, 2-3% P₂O₅, 1-2% K₂O) and structural materials based on oxide impurities (SiO₂, Al₂O₃, Fe₂O₃) used as a support for a new vanadium catalyst.The developed gas purification system ensures 99.5% efficiency in ammonia capture, enabling its return to the technological cycle.The findings confirm the feasibility of industrial implementation of the proposed technology, with potential integration into existing sulfuric acid production facilities, thus enabling environmentally safe disposal of SVCs while simultaneously generating commercially valuable products.

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