Abstract
Catalytic reforming with continuous catalyst regeneration (CCR) is one of the key processes in the production of high-octane gasolines. The need to improve its energy and resource efficiency while complying with modern environmental standards remains a relevant and pressing issue. Particularly challenging is the development of accurate mathematical models of this process under industrial operating conditions, considering catalyst degradation, fluctuations in feedstock composition, and significant thermal effects. The purpose of the article is to develop and calibrate a mathematical model of the CCR reforming process using Aspen HYSYS, demonstrated through a case study of the Atyrau Refinery. The research methodology includes the collection of operational data (feedstock composition, reactor parameters, catalyst properties), construction of a detailed process flowsheet, thermodynamic modeling, and calculation of material and energy balances. The developed model was calibrated using actual industrial data and tested for reproducibility and predictive accuracy. The results confirm that the proposed model reliably predicts reformate yield and octane number, as well as identifies optimal process parameters under variable production conditions. The article emphasizes the technological advantages of CCR reforming, including high process stability, extended catalyst service life, and improved energy efficiency. The practical significance of the research lies in the possibility of applying the developed model to optimize the operation of existing CCR units and for the training of engineering personnel. The proposed approach can also be adapted for other refineries with similar technological configurations.