Acetylene is one of the byproducts of olefin plants with the potential to poison the catalysts in polymerization plants, which can be avoided by reducing the acetylene concentration to less than 1 ppm. Catalytic hydrogenation in tail-end systems is the method most commonly used in the industry to eliminate the acetylene. The Pd/Ag/alpha-Al2O3 catalysts used in this process undergo moderate deactivation due to coke and green oil formation, necessitating their regeneration after certain runtimes. The domestic petrochemical plant which has been investigated in this research is an olefin plant. Close monitoring of the two regeneration cycles in this plant, have revealed complications that caused a dramatic reduction in catalyst lifetime and also disrupted the temperature profile in the reactor overtime. In the present study, a new configuration of regeneration process is suggested based on inspecting the conventional protocol and a comparative analysis to other plants. The results emphasize the need to reconfigure the reactors and pipelines in order to achieve complete regeneration throughout the reactors. (C) 2012 Elsevier B.V. All rights reserved.