Making precious metals cheap: A sonoelectrochemical - Hydrodynamic cavitation method to recycle platinum group metals from spent automotive catalysts

Platinum group metals, such as Pd and Pt, found in three-way catalyst converters were recycled in a two-step method: hydrodynamic cavitation followed by sonoelectrochemical dissolution. High shear forces were obtained by using a convergent nozzle with a throat diameter of 0.2 mm, feeded by a plunger pump at a pressure of 60 MPa. Cavitating submerged jets acted locally on the water dispersed waste catalyst. As-obtained samples were analyzed by scanning electron microscopy and transmission electron microscopy. Electron microscopy on the initial sample showed that round shaped Pd and Pt nanoparticles were randomly distributed on the Al₂O₃ matrix. Cavitated samples show two zones in which Pt and Pd were partially and completely separated from the cordierite. The hydrodynamic cavitation separates the Pd and Pt from the cordierite leading to an apparent increase in Pd and Pt concentrations of 9% and 34% respectively. Conventional electrochemistry showed a dissolution of 20% in 1 h. To further accelerate the dissolution, a sonotrode operating at 20 kHz and 75 W was placed inside an electrochemical cell in order to increase the mass transport and obtain high dissolution rates. Indeed, the results showed that 40% of the available Pd and Pt can be recycled in just 1 h. In the absence of hydrodynamic cavitation and using conventional electrochemistry less than 10% of the available Pt and Pd is recovered in 1 h. The cost analysis showed that Pd and Pt can be recovered at less than 10 EUR per g which is 5 times smaller than their current market price.