Merox Catalyst

Merox Catalyst

The catalyst used in the mercaptan treatment process, commonly known by the same name, is referred to as the Merox catalyst. The Merox process is used for the treatment of mercaptans in oil, gas, gas condensate, and hydrocarbon streams in general.

What Are Mercaptans?

Mercaptans are sulfur-containing compounds associated with hydrocarbon structures. Based on their general chemical formula, they are also represented as RSH compounds.

Mercaptans are well known for their strong and unpleasant odor. They can also be toxic, corrosive, and harmful to the environment.

Both light and heavy mercaptans may be present in different hydrocarbon fractions. Mercaptan compounds can be found across a wide range of hydrocarbon streams, from very light hydrocarbons to crude oil.

Because of their undesirable properties, mercaptans are generally removed, separated, or chemically converted during the early stages of oil and gas processing and refining.

Merox Process

In the oil, gas, and petrochemical industries, the process through which mercaptans are removed from or treated within a hydrocarbon feed is commonly referred to as the Merox process.

During the Merox process, and in the presence of a Merox catalyst, mercaptans react with oxygen and are converted from RSH compounds into RSSR compounds, or organic disulfides.

The general reaction can be represented as:

2RSH + 0.5O₂ → RSSR + H₂O

Disulfides do not exhibit the same undesirable properties as mercaptans, particularly in terms of odor and corrosiveness.

The Merox process was originally introduced in the United States and became widely known under the Merox name. Today, several experienced catalyst manufacturers produce catalysts for mercaptan oxidation and sweetening processes under different commercial names and technologies.

Examples include catalyst technologies associated with:

Axens

Merox

IVKAZ

The IVKAZ catalyst, developed by the Russian petroleum research institute VNIIUS, is used in mercaptan treatment processes for the purification of crude oil, petroleum products, gas, and gas condensate.

IVKAZ mercaptan-removal and sulfur-treatment catalysts have been applied in several oil, gas, gas-condensate, and petrochemical facilities, including the South Pars Gas Complex, Persian Gulf Star Oil Refinery, and Persian Gulf Bid Boland Gas Refinery.

AAprolab is the exclusive representative and licensed manufacturer of IVKAZ and VNIIUS products in Iran. By producing this cost-effective catalyst locally under license and in accordance with the original manufacturer's quality requirements, the company has contributed to domestic engineering capability, job creation, and the treatment and upgrading of petroleum products in Iranian refining and processing complexes.