We have a regenerated batch of 1.3mm QL-shape hydroprocessing catalyst with an average particle length of only 2.5mm. Can it be re-used?

Re-use of a short catalyst can cause pressure-drop problems. In addition to the average particle length (APL), you should also examine the particle size distribution (proportion of shorts <1.5mm and proportion <2.0mm), the compacted bulk density (CBD), the particle density and the void fraction, in combination with the unit requirements. If the specification is borderline, screening or length grading can be considered, in which the short particles are selectively removed to increase the APL and void fraction. Qualified vendors can offer that service and give a guarantee/prediction of expected losses and specification of the material obtained. Please note that the product’s CBD will be lower and additional make-up catalyst will be required.