This project, completed at a cost of less than 200 billion rials, not only prevented the country from incurring expenses exceeding 4,664 billion rials for the purchase of new equipment, but also clearly demonstrated the resilience and creativity of Iran’s petrochemical industry in confronting complex technical and economic challenges. This achievement added yet another golden page to the honors of Shiraz Petrochemical Company and paved the way for enhanced efficiency and self-sufficiency in this strategic industry.
The Importance of the “Transfer Line” Structure and the Challenges of Its Repair
“Transfer lines” in ammonia and methanol production units are considered vital arteries. These bottleneck pieces of equipment are responsible for transferring hot reformed gas and, due to the high risk of explosion and fire, play a critical role in ensuring safe and continuous production. The challenges and heavy costs associated with procuring spare parts—especially under unjust sanctions—have always been a serious concern for petrochemical industries.
With more than six decades of operation, Shiraz Petrochemical Company, as one of the country’s largest petrochemical complexes, plays a key role in the production of ammonia and a wide range of other products. Liquid ammonia, as the main raw material for nitrogen-based chemical fertilizers, has a strategic role in ensuring national food security.
The ammonia production process requires high temperatures and pressures. The transfer line, which carries reformed gas at an average temperature of 765°C and a pressure of 30 bar, is therefore highly sensitive. The design temperature of the equipment’s metal shell is 300°C, and to control temperature, its inner wall is lined with two layers of refractory material.
Any damage to these layers leads to increased shell temperature, risk of explosion and fire, and production shutdowns. Due to technical complexities, the maintenance and repair of these lines have always been difficult and challenging, and in most cases, complete replacement of the equipment has been considered the only viable option.
Creativity and Innovation at the Heart of the Most Challenging Repairs
Since its commissioning, the transfer line of Ammonia Unit 3 at Shiraz Petrochemical Company had faced challenges related to increased shell temperature at various points. Even with the installation of multiple cooling fans, temperature control remained difficult due to weaknesses and damage in the refractory layers. Given these conditions and the importance of maintaining continuous production, repairing this equipment was placed on the agenda.
During emergency repairs caused by a gas cut in the winter of last year, this opportunity was seized to adopt a creative approach. By leveraging the knowledge and valuable experience of internal experts, instead of purchasing a new transfer line, the horizontal section beneath the reformer was repaired and rebuilt. This smart decision not only prevented prolonged production stoppages and exorbitant costs, but also proved the complex’s capabilities in handling difficult maintenance and repair conditions.
An Achievement for the History of the Petrochemical Industry
This repair masterpiece is considered a major achievement for Shiraz Petrochemical Company and for the country’s petrochemical industry as a whole. Significant cost reductions, increased efficiency, and the documentation of a valuable experience in the repair of bottleneck equipment are among the outstanding outcomes of this initiative. This success confirms the fact that by relying on domestic capabilities, knowledge, and creativity, even the most difficult challenges can be overcome, paving the way toward self-sufficiency and progress in the petrochemical industry. This event will undoubtedly stand as another golden page in the history of Iran’s petrochemical industry.
This great success is the result of the tireless efforts and high commitment of all employees and dedicated specialists of Shiraz Petrochemical Company. Esteemed colleagues in both operational and non-operational units, through their expertise, dedication, and exemplary spirit of cooperation, played a key role in achieving this major accomplishment. This event will undoubtedly inspire future generations of the nation’s industrial professionals