Kdison Technical Team Analyzes Catalyst Deactivation in an Indonesian Hydrogen Peroxide Plant: Environmental Sulfur Pollution Identified as the Primary Cause

In June 2025, during technical support activities for a hydrogen peroxide production plant in Indonesia, Kdison identified an abnormal decline in the activity of a palladium-based catalyst used in the unit. This resulted in reduced hydrogenation efficiency and a noticeable impact on plant output. Following systematic analysis and independent verification, the incident was confirmed to be a relatively rare case of catalyst deactivation in the hydrogen peroxide industry, caused not by process or equipment defects, but by external environmental factors.

The project adopts the fixed-bed anthraquinone process for hydrogen peroxide (H₂O₂) production provided by Kdison. This process has been widely and reliably applied worldwide for many years. The plant design is mature, operating parameters are reasonable, and the unit operated smoothly during the initial period after commissioning.

After the issue emerged, Kdison’s technical team immediately conducted a comprehensive review of operating data, process conditions, and operating practices. Based on long-term engineering and operational experience, the team preliminarily concluded that the catalyst deactivation was likely related to abnormal ambient air quality, particularly the presence of sulfur-containing contaminants. Although such a conclusion is uncommon in the hydrogen peroxide industry, it was technically reasonable considering the environmental conditions surrounding the plant.

To further verify the scientific accuracy and objectivity of this judgment, Kdison proactively transported the suspected poisoned catalyst samples from Indonesia to China and commissioned independent third-party laboratories to carry out comprehensive physicochemical analyses. The testing program, which lasted several months, included SEM, BET, EDS, ICP-MS, IC, and XPS analyses.

In September 2025, the third-party test reports were officially released. The results from multiple analytical methods consistently confirmed that the sulfur content in the catalyst had increased significantly, and that sulfur was present mainly in the form of +6 oxidation state sulfates. These sulfates strongly adsorb onto palladium active sites, forming stable surface compounds that inhibit hydrogen adsorption and activation, leading to typical sulfur poisoning–induced catalyst deactivation. The analytical conclusions were fully consistent with Kdison’s initial technical assessment.

The plant is located within a chemical industrial park, surrounded by multiple chemical facilities. Investigations showed that some neighboring plants exhibited insufficient exhaust stack height and inadequate off-gas treatment, allowing sulfur-containing hazardous gases to disperse locally and enter the ambient air. In the anthraquinone process, the oxidation stage requires continuous air intake. Sulfur pollutants in the air are gradually converted within the system into sulfate species (SO₄²⁻), which circulate with the working solution, enter the hydrogenation section, and ultimately accumulate on the surface of the palladium catalyst.

The most direct impact of catalyst deactivation is a reduction in hydrogenation efficiency. Once palladium active sites are covered, the hydrogenation conversion of anthraquinone derivatives decreases significantly, limiting working solution circulation efficiency and ultimately resulting in reduced hydrogen peroxide production capacity. The impact is mainly reflected in production efficiency rather than plant safety, but it poses a material challenge to continuous and stable operation.

After the root cause was conclusively identified, Kdison’s technical team proposed a tiered set of countermeasures to the client, taking into account engineering feasibility and economic considerations:

1.Air Treatment and Purification Solution

Installation of air purification and adsorption systems upstream of the oxidation air intake to remove sulfur-containing contaminants. While technically effective, this option involves relatively high capital and operating costs.

2.Engineering Layout Optimization for New Projects

For new hydrogen peroxide plants, environmental conditions should be fully considered at the design stage, with air compressors and intake points located as far as possible from potential pollution sources. This measure is not practically applicable to existing plants.

3．Interim and Transitional Measures

Under current conditions, targeted cleaning and treatment of sulfur-poisoned catalysts can partially restore catalytic activity, ensuring continued plant operation.

Kdison’s technical team emphasized that this case demonstrates how, in high-standard, continuously operated hydrogen peroxide plants, overall industrial park environmental conditions have become a critical “hidden process parameter.” Although catalyst deactivation caused by external environmental factors is uncommon in the industry, it carries important engineering implications for fine chemical plants.

As a specialized provider of hydrogen peroxide EPC turnkey solutions, Kdison remains committed to engineering-driven innovation and continuous improvement in environmental adaptability, delivering safe, reliable, and sustainable hydrogen peroxide production technologies to clients worldwide.