Investigating the Effect of Temperature and Pressure Changes in CCR Unit Reactors on Catalyst Wear and Black Dust Increase

Continuous Catalyst Regeneration (CCR) units play a critical role in the naphtha reforming process, maintaining catalyst activity and process efficiency. This study investigates the influence of these parameters on catalyst wear and the formation of black dust—a fine particulate byproduct composed mainly of eroded catalyst particles and coke residues. Data was collected over six months from an industrial-scale CCR unit, including operational variables such as inlet/outlet temperature, reactor pressure, and measured quantities of catalyst loss and black dust. Using multiple linear regression and ۳D surface analysis, the study reveals a strong positive correlation between elevated temperatures (above ۵۲۰°C) and black dust generation, while lower reactor pressures (<۲.۰ bar) were found to exacerbate catalyst attrition. The regression model, with an R² value of ۰.۸۷, suggests that both variables significantly predict the formation of black dust. Visual analysis through ۳D modeling further emphasizes the interactive effect of temperature and pressure on catalyst degradation. The findings highlight that stable operation within the range of ۵۱۰–۵۱۵°C and pressures above ۲.۲ bar can reduce catalyst wear and minimize environmental and operational issues related to dust formation. This study provides valuable insights for refining engineers and plant operators, offering recommendations for process optimization to prolong catalyst life, improve unit reliability, and reduce maintenance costs associated with particulate emissions.

کلیدواژه ها:

Temperature ، Pressure ، CCR Unit ، reactor ، Catalyst Wear ، Black dust increase