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An Invaluable Achievement by a Knowledge Enterprise: Increment in Sulfur Uptake in Petrochemical and Steel Industries
Desulfurization catalysts containing zinc oxide nanoparticles are the most widely used and important adsorbents for desulfurization and removal of hydrogen sulfide (H2S) from natural gas, synthesis gas and carbon dioxide flow in petrochemical and steel industries.
The devastating effect of hydrogen sulfide on the performance of the catalysts used in steel, refinery and petrochemical units, especially the catalysts developed for reforming and the water gas shift is in such a way that may cause a drastic decrease in the catalyst activity temporarily or permanently as well as the rate of production and other processing parameters. Other disadvantages of introducing the sulfur into the reactors may include the reduced lifetime of the catalysts used in the reformers producing reduced gas.
The important properties of adsorbents comprise the proper charge density, the high strength components, the optimal specific surface area, the adequate pore size and volume, the high sulfur uptake capacity, the low friction and wear of the components (the production of slight powder due to the passage of gas through the bed) and the pressure drop of the bed. It is not possible to obtain the highest level for all these parameters simultaneously due to the natural contradiction, and the optimal value for these physical and chemical properties can be appointed only with respect to the processing and operational parameters of the adsorbent for the removal of H2S from the gaseous stream.
In other words, the production of a sorbent that can be used for all processes having the best performance in the removal of sulfur is not possible and the adsorbents used in refineries, petrochemicals, gas, and chemical units, and direct reduction unit are different. It has been practicable to adjust and optimize these properties during the production process by making changes in the type of synthesis, calcination, material molding and mixing parameters.
Producing desulfurization adsorbents containing nanoparticles definitely brings about a higher specific surface area, higher sulfur uptake at a constant value of zinc oxide, more stable performance with time, and indirectly production of more solid and robust components. Reduced size of the zinc oxide particles and their fine distribution can also give rise to a greater absorption of sulfur without increasing reactor temperature in higher feed flow rates, i.e. higher transmission rates (less retention time).
The production method is initially to prepare zinc oxide nanoparticles with proper properties (proper specific surface area and pore volume) with a particular process. The oxide produced is then mixed with suitable binders, and the extrusion molding is then carried out by adding appropriate additives such as a lubricant, suitable moisture, and a specific binder. The adsorbent must then get dried and calcified at a suitable temperature to achieve a specific surface area, density and amount of pore volume onto obtaining the final product.
Among the properties of the product which have been promoted due to the use nanotechnology, it can be noted to the increased specific surface area, sulfur uptake capacity, strength, and wear of components.
Some competitive advantages of the catalyst produced by Kharazmi Technology Development Company compared to other manufacturers to be considered are the higher sulfur uptake in a constant amount of temperature and feed gas flow rate, a higher specific surface area, appropriate strength and low friction and wear of the components.
In general, other competitive advantages of the product made by Kharazmi Technology Development Company compared with the existing ones in the market include the appropriate product price in comparison to similar imported catalysts, more efficient and higher performance in sulfur uptake, higher levels of specific surface area for sulfur uptake in higher feed flow rates, proper strength of components during transportation and loading and during the process, low wear of produced adsorbent by the passage of gas through the reactor and the lower pressure drop inside the reactor due to the low wear of the components.
Daily production of 2 tons of desulfurization zinc oxide nanocatalysts
Kharazmi Technology Development Company as an active knowledge enterprise performs in the field of research, development, and production of various sorbents and catalysts in the refinery, petrochemical and steel industries, as well as the recovery of base metals from used catalysts. The company has been able to conclude several contracts with production units for producing the catalysts and has sent many catalysts' cargoes to industrial units. These catalysts are now active in these units and have functioned quite well as comparable with foreign products.
The evaluation of nanoscale product and the issuance of a nanoscale certificate were made by the Nanotechnology Initiative Council after sampling the product being manufactured from the industrial production line.
The product has undergone all stages of laboratory, semi-industrial and industrial processes, and the production line of this product is launched with a nanoscale certificate on an industrial scale with daily production of 2 tons of product. Currently, two shipments with a total of 200 tons of orders have been received and delivered.
Kharazmi Technology Development Company has been able to directly employ 20 people through its production line with a capital of 150 billion IRR and would earn 40 billion dollars from the sale of this product in 1396 (2017).
Currently, the market need for desulfurization adsorbents in the country is 1000 tons per year, estimated to reach 1500 tons in terms of development projects in various industries. The output of Kharazmi Technology Development Company is currently 1000 tons per year, which can be doubled in capacity.
Among the contracting companies for the consumption of the product, it can be referred to Khuzestan Steel Company and Mines and Metals Technology Engineering (MMTE) Company for the direct reduction unit of Gol Gohar (Kosar and Gohar).
In addition to obtaining a nanoscale certificate from the Tech-Market Service Corridor, this product has succeeded in successfully completing the physical-chemical tests and the high absorption capacity by the Research Institute of Petroleum Industry.
The presentation of the product at domestic conferences such as the Iranian nitrogen plus syngas conference in Iran, along with various domestic exhibitions such as the International Oil, Gas and Petrochemical Exhibition, Steel Industry Outlook Exhibition, IFP Exhibition, Abu Dhabi International Petroleum Exhibition and Conference (ADIPEC) (one of the most prestigious exhibitions in the field of products used in the petroleum industry), technology exhibitions, growth centers, science and technology parks, and Iran Nano Exhibitions have been such activities undertaken to introduce the product.
In addition to these actions, visits by various experts from the industrial production units of the country (refineries, petrochemicals, steel, etc. units) also play a vital role in the introduction of this product.