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A series of low HgCl₂-supported catalysts (K-TX-O, K-WG-O, K-S20-O, K-S40-O, K-Fe0.8-O, K-Fe0.8-M, D-Fe0.8-M) was prepared and investigated for C₂H₂ catalytic abatement during highly purified HCl (HP-HCl) production process. The samples of D-Fe0.8-M, K-Fe0.8-M, and K-Fe0.8-O were found to exhibit much higher activities and better thermal stabilities than those of other samples. The characterization results of XRD, N₂ adsorption/desorption, SEM, back scattered electron (BSE) and thermogravimetry (TG) revealed that: (i) the larger mesoporous volumes constituted one of the key factors leading to superior catalytic performances of D-Fe0.8-M, K-Fe0.8-M, and K-Fe0.8-O, which greatly facilitated better dispersions of the loaded HgCl₂ species in comparison to other samples; (ii) the KCl additive could further improve the dispersions and thermal stabilities of the loaded the HgCl₂ species due to the strong interactions between KCl and HgCl₂ species, resulting in relatively higher catalytic behaviors of D-Fe0.8-M and K-Fe0.8-M than that of K-Fe0.8-O; (iii) the KCl/HgCl₂ step-by-step loading strategy, wherein the KCl was initially loaded on the Fe0.8-AC substrate thereafter followed by HgCl₂ loading, could further improve the catalytic behavior for D-Fe0.8-M due to additional improvements of HgCl₂ dispersions. The deactivation and reactivation of D-Fe0.8-M during HP-HCl were also investigated, which suggested that partial deactivated D-Fe0.8-M by C₂H₃Cl accumulation could be efficiently reactivated by HCl treatment at T = 220 °C. Full article