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Indigenized catalyst loaded at Shahid Kharrazi mega-module


An operation was successfully carried out to repair Mega-Module A of the Direct Reduction Unit of Shahid Kharrazi project and use indigenized catalysts to load reformer catalysts at the facility's mega-module, said the head of Shahid Kharrazi Direct Reduction Unit (No. 2).
Mohammad-Reza Fathi further said, “Originally the annual repair was expected to last 30 days, but thanks to close cooperation between all units it was completed in 27 days. The project, which took 75,000 man-hours to complete, was carried out in full compliance with safety standards.”
As part of the project, he said, the following measures were handled: overhaul of reformers; replacement of catalysts and the furnace’s feed legs; and reconstruction of refractory doglegs. “The operation to load reformer catalysts with indigenized catalysts in Shahid Kharrazi mega-modules amounts to a major breakthrough for the steel industry.”   
Fathi went on to say that the unit has resumed its real production capacity following the overhaul. “Undoubtedly the operation owes its success to the contribution of different units such as procurement, technical logistical services, refractory, operations, and iron making, as well as executive contractors. We are grateful to all of them.”
For his part, Nader Orujnezhad, who heads repair operations at the Direct Reduction Unit, said the overhaul in question has been one of the biggest annual repairs in terms of man-hours, and the volume of mechanical and electrical activities as well as instrumentation and refractory.
Meanwhile, Hamid-Reza Bozar, who leads the team in charge of logistical support for mechanical repair, said this is the first time in Mobarakeh Steel Company that the annual repair of a Direct Reduction Unit mega module involves so many people and major activities as such. “To safely and qualitatively handle the annual repair which triggers a stoppage in the unit, we needed to take effective measures when it came to management, engineering, risk assessment for activities and functions, and organization of the workforce.”
He said other measures were taken such as charging catalysts (480 tubes and 25,920 man-hours), furnaces, top gas, cooling gas, compressors, pumping stations, and رکلدر. “Later, the mega module A was made available to Direct Reduction Unit No. 2 to be inaugurated.”
He said this big achievement has come on the back of efforts by all staff members who selflessly and zealously helped the production process at MSC. “I would like to thank them all for the efforts they have put in.”
Meanwhile, Mohsen Zamani, the head of the refractory repair services unit at MSC, said six years after the construction and inauguration of Module A, the production unit decided to change reformer catalyst tubes. “Then, a process got underway to cool reformers, disassemble and replace all refractory parts such as heat diffusers, اینسرکن, suspension trumpet, doglegs, and the joints of line headers and doglegs. As a result the stage was set for the refractory repair unit to make joint meticulous planning with the production unit, Shahid Kharrazi’s Direct Reduction repair unit and central repair unit to take care of refractory work inside and outside the reformers and fix the blankets installed in ceiling and side and transverse walls inside the reformers.”                


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