RoydadNaft –  Bu Ali Sina Petrochemical Complex has successfully completed a major overhaul of key reactors in its aromatic and paraxylene units without halting production, enhancing equipment reliability and operational efficiency.

Omid Azmian, the complex’s general manager, said: “Reactors 4002 and 4004 in the aromatic unit—untouched since the plant’s launch in 2004—underwent their first major maintenance after 20 years. Internal damage and catalyst leakage had significantly reduced efficiency, but with Iran’s domestic engineering expertise and local contractors, they have been fully restored to optimal performance.”

In a 20-day operation involving over 44,200 man-hours and zero safety incidents, the project targeted production bottlenecks while maintaining full output, Azmian told state news agency Shana. Beyond the two critical reactors, technicians overhauled Reactor 3001, Reactor 4003, a plate heat exchanger in Area 400, spherical tank 4002, and multiple operational heat exchangers—all in strict compliance with health, safety, and environmental (HSE) standards.

Production Continues Uninterrupted

“Throughout the turnaround, select units remained online while repairs proceeded in parallel sections,” Azmian explained. “This was achieved through precise coordination among technical, operations, and safety teams, ensuring uninterrupted product flow, quality, and worker safety.”

Additional work included cleaning process systems, fixing heat exchanger leaks, replacing catalysts in Reactor 3001, and routine electrical and instrumentation checks to sustain stability across all production layers.

Azmian hailed the effort as a “team triumph of knowledge management and collective commitment,” positioning Bu Ali Sina as a model for in-service maintenance across Iran’s petrochemical sector. “We can now stabilize output beyond nameplate capacity, setting a benchmark for peers nationwide,” he added.

One of Iran’s largest petrochemical producers, Bu Ali Sina specializes in aromatics and paraxylene, vital feedstocks for plastics and synthetic fibers. The overhaul underscores the industry’s push for self-reliance amid international sanctions.