Investigating the Effect of Temperature and Pressure Changes in the Isomerization Unit Reactor on Catalyst Crushing and Catalyst Cake Formation

This study explores the effects of temperature and pressure variations on catalyst degradation mechanisms specifically catalyst crushing and catalyst cake formation in a light naphtha isomerization unit. Operating conditions within the range of 200–280°C and 10-35 bar were simulated to evaluate mechanical and physical stress on the catalyst bed. Two performance indices were defined: the Catalyst Crushing Index (CCI) and Catalyst Cake Thickness (CCT). Results revealed that both CCI and CCT increase significantly with rising temperature and pressure, with pressure having a more pronounced impact. Elevated pressure intensified catalyst compaction, while temperature contributed to structural weakening and sintering. The analysis showed that high-pressure environments above 25 bar and temperatures exceeding 260°C led to accelerated crushing and cake buildup, contributing to pressure drop, pore blockage, and reduced hydrogen diffusion. These degradation mechanisms ultimately reduce catalytic activity and operational efficiency. The findings suggest that maintaining optimal reactor conditions and incorporating real-time monitoring systems are essential for preventing early catalyst failure. This research provides a predictive framework for improving catalyst performance and life cycle in isomerization processes and can support operational decision-making in refinery settings.