In an unprecedented and inspiring move, Shiraz Petrochemical Company, relying on local knowledge and domestic capabilities, succeeded in repairing and renovating part of the critical “Transfer Line” of Ammonia Unit 3. This project, which was completed at a cost of less than 200 billion rials, not only prevented the country from incurring a cost of 4,664 billion rials to purchase new equipment, but also demonstrated a clear example of the resilience and creativity of Iran’s petrochemical industry in the face of difficult technical and economic challenges. This success adds another golden leaf to the honors of Shiraz Petrochemical Company and paves the way for improving productivity and self-sufficiency in this strategic industry.
The Importance of “Transfer Line” Construction and Its Repair Challenges
“Transfer lines” are considered lifelines in ammonia and methanol production units. These bottleneck equipment are responsible for transporting hot reformed gas which plays a vital role in safe and continuous production due to the high risk of explosion and fire. The difficulties and high costs of purchasing spare parts due to the oppressive sanctions have always been a serious concern for the petrochemical industries.
Shiraz Petrochemical Company, with more than six decades of activity and as one of the largest petrochemical industries in the country, plays a key role in the production of ammonia and a wide range of other products. Liquid ammonia, as the main raw material in the production of nitrogenous chemical fertilizers, plays a strategic role in ensuring the country’s food security.
The ammonia production process requires high temperatures and pressures, and the “transfer line” is highly sensitive due to the transfer of reformed gas with an average temperature of 765 degrees Celsius and a pressure of 30 bars. The design temperature of the shell metal of this equipment is 300 degrees Celsius, and its inner wall is covered with two layers of refractory to control the temperature.
Any damage to these layers will lead to increased shell temperature, explosion and fire, and production stoppage. Maintenance of these lines has always been difficult and challenging due to technical complexities, and in most cases, complete replacement of the equipment has been the only option.
Creativity and innovation in the most difficult repairs
The “transfer line” of Shiraz Petrochemical Ammonia Unit 3 faced the challenge of increasing the shell temperature in various places since its launch. Even despite the installation of multiple cooling fans, temperature control was difficult due to weakness and damage in the refractory layers. Considering these conditions and the importance of continuing production, repairing this equipment was put on the agenda. During emergency repairs due to a gas outage last winter, this opportunity was taken to repair and reconstruct the horizontal section under the reformer with a creative approach and by utilizing the valuable knowledge and experience of domestic experts, instead of purchasing a new transfer line. This smart decision not only prevented a long-term production stoppage and imposing excessive costs, but also proved the complex’s capabilities in facing difficult repair and maintenance conditions.
An achievement for the history of the petrochemical industry
The repair masterpiece is considered a huge achievement for Shiraz Petrochemical Company and the entire petrochemical industry of the country. Significant cost reduction, increased productivity, and recording valuable experience in the field of bottleneck equipment repairs are among the brilliant results of this initiative. This success confirms the fact that by relying on domestic power, knowledge, and creativity, the most difficult challenges can be overcome and the way for self-sufficiency and progress in the petrochemical industry can be paved. This event will undoubtedly be another golden leaf in the history of the Iranian petrochemical industry.
This great success is due to the relentless efforts and great dedication of all the committed employees and specialists of Shiraz Petrochemical Company. Valuable colleagues in operational and non-operational units, with their expertise, commitment and exemplary spirit of empathy, played a key role in achieving this great achievement. This event will undoubtedly inspire future generations of industrialists in the country.
