This investigative study focuses on the health of industrial catalysts and the strategies required to minimize their attrition and deactivation in petroleum refining and petrochemical processes. Catalyst performance is a key driver of process efficiency, product yield, and overall plant economics. However, catalysts are subject to several degradation mechanisms, including mechanical attrition, fouling, sintering, poisoning, and thermal deactivation, which significantly reduce their activity and selectivity over time.