Araz Silicon araz innovative entrepreneurship

First. Generating Industrial Value Added in Mine Sector

Considering ever-increasing of clean energy demand (particularly, solar energy according to radiation potentials in Iran) and increase of living standards, as well as increasing growth of silicon element-based industries, the need to develop silicon value chain in the country is inevitable. Replacing the solar energy as the greatest source of clean and inexpensive energy in the world and using raw materials based on silica ore in the industry has caused Araz Silicon Industries to take substantial actions in the field of producing raw materials of solar cells and the associated industries and then establishing solar power plants. In line with this, large complex of factories for producing industrial silicon, polysilicon, solar cells and solar panels will create a lot of jobs in addition to preventing the currency exit, and chain value of silicon industry from extraction of industrial silicon from ore to producing solar panel and establishing solar power plant will be fulfilled. In fact, Araz Silicon Industries Campus consisting of a group of elites (5 university faculty members and 7 medal winner of scientific Olympiads of the country) and industrial activists of the country with brilliant records and different abilities in different scientific, industrial, commercial and economic areas intends to create the complete chain of silicon industry from extracting 99% silicon from ore to producing solar panels and all types of silicon polymers in the country with a knowledge-based approach with the following 10-year vision. Industrial silicon, as the first product in silicon value chain, has reached to the production stage in Araz Silicon Industries Company for the first time in Iran and the Middle East. Industrial silicon, as the main product of the process, is an extremely important and strategic product in industry chain and is considered as one of the most versatile upstream products in the industry and has gained the title of the most important functional material in semi-conductors industry, electronic information industry and industry of solar photovoltaic cells of the new energies and new materials industries. Industrial products resulting from are of different types and include a wide range of areas. In industry, they are known as magical products to the extent that in China, which has a share of around 64% in global production of this product, this product is considered as the one of the pillars of China’s economic reconstruction. According to experts, generation of photovoltaic energy in the middle of and late 20th century will be one of the most important initial sources of energy for human beings. Therefore, creating a high basis to start producing large-scale industrial silicon has a strategic importance in the long-run for generation of photovoltaic electricity and even adjusting the energy structure. Thus, the country’s activity in production of industrial silicon according to any of the following cases has had a production property in product.

Despite being a strategic product (industrial silicon), it is for the first time in the country and the Middle East that this product has reached to implementation and production stage. Tight now, Araz Silicon Industries Campus Complex operates ad the strongest team in the field of industrial silicon production in the country and by implementing phase 1 of the factory, much of the project’s know-how has been localized. The history unsuccessful attempts to produce industrial silicon in the country goes back to more than two previous decades but now this product has been produced in Araz Silicon Industry Company in less than 2 years. In fact, in addition to the fact that this product has been produced for the first time in the country, it is considered as an added value and a processed product in the field of mining.

The amount of consumption of industrial silicon in the country is equal to 10 thousand tons per annum which is completely imported to the country and this has the exit of more than 30 million dollars per annum from the country.

At the same time with launching the factory and initial operation with a capacity of 14 thousand tons per year, 250 persons will have direct employment and by completing the phase 1 and with the annual production of 40 thousand tons of industrial silicon, 600 persons will be employed directly.

By designing and planning the development of target market of this product as follows, it has a justifiable capacity to export the product and earn foreign currency. ⦁ 10 percent domestic (given the import statistics of industrial silicon in the country) ⦁ 90 percent foreign (Germany, European League, Persian Gulf Border Countries)

Undoubtedly, the responsibility of organization is not to be effective merely, but they should serve the community in which they operate. In line with this, social responsibility is essential for project management and covers all stages from phase zero and preliminary phase up to project implementation. In addition to physical design and investment and production specifications, the managers should consider the side effects of the activities and allocate part of the project resources to the topic of social responsibility and take care the surrounding environment suffers from no harmful effects. In today’s business paradigm, success secret of the large companies is not only profitability for shareholders and performance of the legal responsibility. But, the beneficiaries expect that the company undertakes economic, social, environmental and ethical responsibilities and be transparent and accountable against them.

Undoubtedly, the responsibility of organization is not to be effective merely, but they should serve the community in which they operate. In line with this, social responsibility is essential for project management and covers all stages from phase zero and preliminary phase up to project implementation. In addition to physical design and investment and production specifications, the managers should consider the side effects of the activities and allocate part of the project resources to the topic of social responsibility and take care the surrounding environment suffers from no harmful effects. In today’s business paradigm, success secret of the large companies is not only profitability for shareholders and performance of the legal responsibility. But, the beneficiaries expect that the company undertakes economic, social, environmental and ethical responsibilities and be transparent and accountable against them.

Product demand forecast for a 5-year horizon: Given the request of the country manufacturing the first and second furnaces and other foreign commercial companies which want to sign contract for pre-purchasing the product at 95 percent of price of FOB Shanghai, the demand exceeds the production and is competitive in the face of global and international products. This is based on long and desirable records of the complex’s management in companies existing in foreign commercial sector. It is predicted that through production and export of phase 1 of industrial silicon, more than $90 million in foreign exchange is realized annually for the country. ⦁ Sustainable Development, Social Responsibility and Solving the Country’s Fundamental Problem In addition to the foregoing, processing and production of this mineral product in Khoy region as a deprived region using the local capacities of the region has been another turning point in knowledge-based innovative activity of Araz Silicon Company. The land for implementing the project is located at Phase 2 of Khoy Industrial Park and its area is more than 171 thousand square meters. In phase 1 of the project, around 30 thousand square meters of the land occupied by the project is for direct employment of 600 persons.

What is considered in Araz Silicon Industries Campus is this point that “social responsibility” is not to do “charitable works” or to make “special support” from some influential local figures and/or other irresponsible actions. Usually, when it comes to social responsibility, the mechanism of satisfying the critics through making them “indebted” is put in the agenda of some managers of the companies. Whereas, “transparency” is considered as one of the social responsibilities of the economic enterprises. In addition to the fact that these measures provide a mechanism for compensating the social and environmental costs of activity to extract and process mineral materials primarily, they improve the relationship of Araz Silicon with the local communities and this way, economic risks of poor relationships with local community is reduced and as a result, production operations are not delayed or even stopped; the point which has clearly been forgotten in economic, mineral and oil activities in Iran or has been gone astray by misunderstanding the concept of “social responsibility.” Our plan in Araz Silicon for social responsibility is in association with the local community and the current elapsed time of the project including construction and commencement of the factory production has also been realized. We intend to have a positive impact on Iran’s fragile environment. So, we have found a way so that development in the minds of people of this land is not synonymous with destruction and intensification of inequality. Exact understanding of “social responsibility” is one of these ways and not all of them. Our belief in Araz is to operationalize the people empowerment plan more than before and this will definitely be greatly welcomed by the people.

Considering that one of the priorities and approach of the knowledge-based companies is in the sectors where the companies export raw materials like mining sector, thus given the production of industrial silicon from mineral materials of the country, this issue has been realized. Unfortunately, in our country there are a lot of problems in mining sector which one of problems is the sale of raw materials. By producing industrial silicon in the country, the processing and added value of silica ore have been created.

Another index of producing industrial silicon is attraction of specialized manpower. In a way that now, the plan to complete phase 1 including 4 other furnaces and other essentials related to it as well as developing the production of industrial silicon will be fulfilled by using acquired knowledge and experience of the specialized team of Araz Silicon.

Second.Innovations in Production Process

Due to high purity of silicon element in it, industrial silicon is very different from similar products such as ferrosilicon. The same distinction creates the need to select the raw materials required for the production. The improved method of thermal stability test of silica ore innovated by Araz Silicon Industries Campus Company greatly helps to better identify the ore required for production of industrial silicon. This method uses statistical method and lithological studies to better identify the high quality silica ore. Later on, due to multiplicity of raw materials used including wood chip (wood charcoal), petroleum coke and coal, we try to control several parameters including the price, the amount of porosity created, electrical resistance, amount of carbon added and suitable reactivity of combining the charge with the effective gases of the furnace for production by optimizing the amount of each substance. This has been obtained in Araz Silicon Company by programming and mathematical studies with the help on linier optimization algorithm and has the ability to be updated according to furnace conditions. Also, reactivity level of any of carbon materials with effective gases in the furnace is one of the most important issues in leading the furnace. Araz Silicon Industries Company as the second company after National University of Norway has gained the knowledge of measuring the reactivity of carbon materials and asserts in this field. After producing the melt of the purification process by blowing oxygen and air as well as adding materials invented by Araz Silicon Company, we try to reduce impurities available in the melt. For this purpose, the scenario of blowing oxygen from the bottom and air mixing rate is performed and while purifying, the additive material is added to the melt. This additive material reduces iron impurities in the melt which is exclusively in the possession of Araz Silicon Company.

Third.Production Complexities and System Integral Performance in Producing the First Industrial Silicon in the Country

To produce industrial silicon (extracting silicon with a purity of 99% from silica ore) a very high temperature is required. Thus, it is produced carbothermically in electric arc furnaces. Raw and auxiliary materials required for producing 99% silicon are as follows:

⦁ Silica ore
⦁ Coal
⦁ Petcoke (petroleum coke)
⦁ Wood charcoal
⦁ Wood chip
⦁ Graphite electrode
⦁ Oxygen gas
⦁ Active carbon

This furnace is the heart of industrial unit and beside it, the following units constitute an industrial unit in addition to the furnace the integral performance of which has been realized.

⦁ Washing unit in which silica and coal are cleaned with water before entering the furnace with the aim of omitting impurities.
⦁ Mixing unit in which raw materials are weighed and mixed before entering the furnace.
⦁ Feeding unit which has the duty to transfer raw materials and charge the furnace.
⦁ Electrical system which has the duty to provide energy of the furnace.
⦁ Off-gas unit cools down extremely hot off-gasses and purifies them and exhausts them from the furnace.
⦁ Cooling unit which has the duty to control temperature of the system.
⦁ Processing unit which purifies, casts, crushes and solidifies the produced silicon.

In fact, electrical energy is transferred to the furnace by the means of three electrodes which are consumed slowly during the process. In melting silicon, prebaked electrodes are usually used, but for large-scale silicon furnaces, composite electrodes (consisting of a graphite core to maintain the strength of electrode and a shell made of cheap carbon paste) have been developed.
Dust removing unit consists of a cooling and a dust filter. Since the main cost of project is the cost of energy, the possibility to recover the energy is available and accessible in this section. Gases inside the furnace are usually SiO and Co which are oxidized into CO2 gas and SiO2 solid as a result of colliding with gases above the charge. This oxidation reaction warms the charge materials entering the furnace and keeps the temperature of upper part of the furnace between 700-1300 Centigrade degrees. High temperature of off-gases improves the efficiency of retrieving energy.
When SiO-rich gas is oxidized silica fume or micro silica is formed. These almost spherical solid SiO2 particles are of average size of 15.0 microns. Micro silica is a side product of silicon industry which is used in cement (micro silica increases the strength and longevity of concrete).