Recovery of V2O5 from Spent Vanadium Catalysts: Materials Insights into Deactivation and Recycling Strategies

Abstract

The growing demand for vanadium and the environmental threat associated with spent catalyst masses have sparked widespread scientific interest in the recovery of V2O5 from deactivated vanadium-based catalysts, including those used in sulphuric(VI) acid production. This review places vanadium(V) recovery in the broader context of resource efficiency and the circular economy. The main deactivation mechanisms are analysed, including poisoning, sintering, and structural changes affecting catalytic activity and vanadium availability. Hydrometallurgical approaches to vanadium recovery are discussed, with a particular focus on leaching agents, vanadium speciation in aqueous media, and subsequent separation techniques such as adsorption, solvent extraction, and vanadium(V) precipitation. Key process parameters influencing recovery efficiency, including temperature, pH, and caustic composition, are discussed to provide a comparative assessment of existing methods. The analysis highlights the advantages and limitations of current recovery methods and identifies gaps related to selectivity, process integration, and environmental impact. Overall, the study demonstrates that effective V2O5 recovery requires a thorough understanding of catalyst deactivation and solution chemistry. It also outlines models for developing more sustainable and economically viable recycling strategies.