Mercury Removal Catalyst

Mercury Removal Catalyst

Product Overview

Mercury contamination in hydrocarbon streams presents significant challenges for industrial processes, including catalyst poisoning, equipment corrosion, and environmental compliance issues. Our mercury removal catalyst is a high-performance solution designed for efficient and reliable mercury removal from a wide range of gaseous and liquid hydrocarbon feedstocks.

Based on advanced spherical alumina technology with precisely engineered pore structure and metal sulfide active components, our catalyst delivers exceptional mercury removal efficiency and high mercury capacity. The small particle size and large pore diameter design optimize mass transfer and diffusion, enabling rapid mercury capture and maximizing utilization of active sites throughout the catalyst particle.

This mercury removal catalyst finds broad application in natural gas processing, liquefied petroleum gas (LPG) treatment, syngas purification, liquid hydrocarbon refining, and naphtha processing. Its high purification efficiency, wide applicability, and reliable performance make it an ideal choice for both new installations and existing facility upgrades, with proven success in numerous petrochemical plants.

Core Technical Principles

Mercury Removal Mechanism

The mercury removal process utilizes chemisorption where elemental mercury and organomercury compounds react with metal sulfide active sites on the catalyst surface. When mercury-containing feedstock passes through the catalyst bed, mercury molecules diffuse into the catalyst pores and react with the metal sulfide active components to form stable mercury sulfide compounds.

The primary reaction converts elemental mercury (Hg⁰) to mercury sulfide (HgS), a highly stable, non-volatile compound securely bound within the catalyst structure. This chemisorption process is highly selective for mercury, allowing other valuable hydrocarbon components to pass through unaffected. For organomercury compounds, the catalyst first facilitates decomposition of the organic mercury molecule, followed by sulfidation of the released mercury.

Catalyst Composition & Structure

Our mercury removal catalyst is based on spherical alumina support engineered to provide optimal physical properties for mercury capture.

Support Characteristics:

• Spherical morphology: Uniform shape ensures optimal bed packing and flow distribution, minimizing channeling and pressure drop
• Small particle size: Shortens the mass transfer zone, improving capture efficiency and increasing utilization of internal active sites
• Large pore diameter: Macroporous structure facilitates efficient diffusion of mercury molecules into the particle interior
• High surface area: Abundant surface area provides ample space for active component dispersion
• Large pore volume: Accommodates significant mercury sulfide deposition throughout the catalyst lifecycle

Active Components:

The catalyst incorporates metal sulfide active phases uniformly dispersed throughout the alumina support matrix. The active components are distributed throughout the pore structure, not just on the external surface, maximizing mercury capacity and extending catalyst service life.

Mass Transfer Optimization

Our catalyst design emphasizes optimized mass transfer characteristics. In traditional mercury removal catalysts, the rate-limiting step is often diffusion of mercury molecules into the particle interior, resulting in underutilization of core active sites.

Our small particle and large pore design addresses this by:

• Shortening diffusion path length for mercury molecules
• Reducing intraparticle mass transfer resistance
• Promoting rapid access to internal active sites
• Minimizing mass transfer zone length in the reactor bed

This optimized mass transfer translates into higher mercury capacity per unit volume and more complete removal at given space velocities, enabling smaller catalyst volumes and longer service cycles.

Key Features & Advantages

High Purification Efficiency

Our mercury removal catalyst delivers exceptional purification performance, achieving very low outlet mercury concentrations that meet the most stringent industry specifications. The combination of highly reactive metal sulfide active sites and optimized mass transfer characteristics ensures efficient mercury capture even at trace inlet concentrations. This high efficiency provides reliable protection for downstream catalysts and equipment.

High Mercury Capacity

The catalyst's large pore volume and well-dispersed active components provide substantial mercury capacity, allowing the catalyst to accumulate significant quantities of mercury before requiring replacement. Higher mercury capacity translates into longer service life, fewer catalyst change-outs, reduced operational costs, and less downtime for regeneration or replacement activities.

Wide Feedstock Compatibility

This catalyst demonstrates excellent performance across a broad range of feedstocks, including natural gas, liquefied petroleum gas (LPG), synthesis gas, liquid hydrocarbons, and naphtha. It operates effectively in both gaseous and liquid phase applications, making it a versatile solution for refineries, gas processing plants, and petrochemical facilities with diverse mercury removal requirements.

Flexible Operating Conditions

Our mercury removal catalyst operates effectively across a range of temperatures, pressures, and space velocities, accommodating variations in process conditions and feedstock characteristics. This operational flexibility allows plants to adjust operating parameters as needed without compromising mercury removal performance, providing greater process resilience and adaptability.

Excellent Mechanical Strength

Manufactured using advanced spheroidization and calcination processes, the catalyst exhibits excellent mechanical strength and attrition resistance. The spherical alumina support provides robust structural integrity, resisting breakage and dust formation during loading, operation, and thermal cycling. High mechanical strength minimizes pressure drop increases over time and ensures consistent performance throughout the service life.

Application Scenarios

Natural Gas Processing

Natural gas typically contains varying mercury concentrations that must be removed to protect downstream equipment and meet pipeline specifications. Our mercury removal catalyst effectively captures mercury from natural gas streams, ensuring compliance with quality standards and protecting cryogenic equipment from mercury amalgamation corrosion.

Liquefied Petroleum Gas (LPG) Treatment

LPG streams require mercury removal to protect downstream catalysts and meet product quality specifications. Our catalyst efficiently removes mercury from LPG in liquid phase operation, achieving very low outlet mercury concentrations. The spherical particle shape and optimized pore structure ensure efficient contact and mass transfer.

Synthesis Gas Purification

Syngas from coal gasification or steam methane reforming often contains mercury that can poison downstream catalysts, particularly in methanol synthesis and ammonia production. Our mercury removal catalyst protects these valuable catalysts by efficiently capturing mercury from syngas streams, extending service life and maintaining process efficiency.

Liquid Hydrocarbon & Naphtha Processing

Liquid hydrocarbon streams and naphtha feedstocks frequently contain trace mercury that causes catalyst deactivation in reforming, hydrotreating, and other downstream processes. Our mercury removal catalyst effectively treats these liquid feedstocks, removing both elemental and organomercury compounds to protect catalytic processes and maintain product quality.

Refinery Applications

In refinery applications, mercury removal is critical for protecting expensive catalysts and preventing equipment corrosion. Our catalyst can be applied at various points in the refinery flow scheme, including upstream of reformers, hydrotreaters, and other catalytic processes, as well as for final product polishing to meet mercury content specifications.

Technical Specifications

Our mercury removal catalyst is available in standard grades to meet various application requirements. Typical specifications include:

Physical Properties

• Physical form: Spherical particles
• Nominal diameter: Standard sizes available for different applications
• Bulk density: Typical range for spherical alumina-based catalysts
• Crush strength: Excellent mechanical strength for reliable fixed-bed operation
• Attrition resistance: Low attrition rate, minimizing fine generation
• Specific surface area: High surface area for optimal active site dispersion
• Pore volume: Large pore volume for high mercury capacity
• Average pore diameter: Large pore design for enhanced mass transfer

Chemical Composition

• Support material: High-purity spherical alumina
• Active component: Metal sulfide active phase, uniformly dispersed
• Active metal content: Typical loading for mercury removal applications
• Purity: High purity, minimizing contamination of treated streams
• Impurity levels: Strictly controlled to ensure consistent performance

Performance Characteristics

• Mercury removal efficiency: High efficiency for both elemental and organomercury
• Outlet mercury concentration: Capable of achieving very low residual mercury levels
• Mercury capacity: High saturation capacity for extended service life
• Operating temperature range: Broad temperature tolerance
• Operating pressure range: Suitable for atmospheric to high-pressure operation
• Space velocity range: Wide GHSV/LHSV tolerance for design flexibility
• Service life: Extended lifespan under normal operating conditions

Note: Specific technical parameters and guaranteed performance values are provided based on individual project requirements, feedstock characteristics, and operating conditions. Contact our technical team for detailed specifications and sizing recommendations tailored to your application.

Operating Instructions

Catalyst Loading

Proper loading is essential for optimal performance. Inspect the reactor vessel to ensure it is clean and dry. Verify support grids, screens, and inert ball layers are properly installed. Load catalyst evenly across the reactor cross-section to ensure uniform bed density and prevent flow channeling. Avoid dropping catalyst from excessive heights to prevent breakage. Record total catalyst weight and bed height for performance monitoring.

Startup & Commissioning

Following loading, gradually bring the reactor to operating conditions. Establish flow through the catalyst bed at controlled rates while ramping temperature and pressure to design conditions. Monitor outlet mercury concentrations during commissioning to verify performance.

Normal Operation

During normal operation, monitor key parameters including inlet and outlet mercury concentrations, pressure drop, feed flow rate, operating temperature, and operating pressure. Regular mercury analysis at the reactor outlet provides the primary indicator of catalyst performance and remaining life. Gradual bed temperature adjustment may be applied as needed to maintain removal efficiency as the catalyst approaches saturation.

Shutdown & Replacement

For planned shutdowns, reduce temperature gradually while maintaining process flow or inert gas purge. Isolate the reactor and maintain positive pressure to prevent air and moisture ingress. When replacement is required, follow proper procedures for catalyst unloading and disposal. Spent mercury-containing catalyst must be handled and disposed of according to applicable environmental regulations.

Precautions

• Keep catalyst dry before and during use; moisture can affect performance
• Store and handle catalyst under inert or non-oxidizing conditions when possible
• Monitor pressure drop — increases may indicate catalyst attrition or fouling
• Periodic mercury analysis helps track catalyst activity and plan replacement
• Use appropriate PPE including gloves, safety glasses, and dust masks when handling

Packaging & Storage

Packaging Specifications

Our mercury removal catalyst is carefully packaged to ensure product integrity during transportation and storage:

• Primary containers: Sealed steel drums or polypropylene bags with inner liners for moisture protection
• Package sizes: Standard and custom packaging sizes available
• Labeling: Each package clearly marked with product name, grade, batch number, net weight, production date, and safety information
• Documentation: Product quality certificate and material safety data sheet (MSDS) provided with each shipment

Storage Conditions

Proper storage preserves catalyst quality and performance:

• Store in a dry, covered warehouse or storage area
• Protect from direct sunlight and extreme temperature fluctuations
• Keep containers tightly sealed to prevent moisture absorption and contamination
• Store on pallets or shelves, not directly on concrete floors
• Avoid contact with acids, alkalis, and other chemical contaminants
• Follow first-in, first-out (FIFO) inventory management practices
• Store in accordance with any applicable hazardous materials regulations

Safety & Handling

• Wear appropriate PPE when handling catalyst, including safety glasses, gloves, and dust masks
• Handle in well-ventilated areas to avoid dust inhalation
• Clean up spilled material promptly to prevent dust accumulation
• Spent catalyst contains mercury and must be handled as hazardous material
• Dispose of spent catalyst according to local, state, and national environmental regulations
• Follow all applicable safety procedures for mercury-containing materials

For technical inquiries, catalyst sizing, or pricing information, please contact our sales and technical support team. Our application engineers are ready to assist with catalyst selection, process design, and operational optimization to meet your specific mercury removal requirements.