About the Client
In industrial environments, particularly in specialty chemical production, the presence of dust can significantly impact product quality and operational efficiency. At SABIC’s Noryl plant, effective dust extraction was crucial to maintaining high-quality standards, reducing the incidence of rejected products, and ensuring customer satisfaction. SABIC partnered with JOA Air Solutions to redesign their dust extraction system, achieving remarkable improvements in both product quality and operational reliability.
Challenge
The Noryl plant, one of SABIC’s oldest, operates with a strong focus on product quality. However, the existing dust extraction system was not adequately controlling dust levels, leading to higher rates of product rejection and customer complaints. SABIC required a solution that would effectively reduce dust in the production process without compromising the efficiency or safety of the plant.
Approach
Initial Assessment and Planning: JOA visited the Noryl plant to conduct a thorough site survey. The team collected vital data on existing airflows, dust particle distribution, and extraction inefficiencies.
Air Technical Modeling: Using in-house developed software, JOA simulated the plant’s airflow and identified bottlenecks. This predictive analysis allowed JOA to design a system with optimal duct routings and extraction capacities, ensuring maximum efficiency.
Design & engineering: Based on the data and simulations, JOA’s mechanical engineering team created a tailor-made dust extraction system. The design integrated proven technologies and was tailored to meet the specific needs of SABIC’s operations, ensuring the system was both efficient and future-proof. read more about Design & Engineering.
System Realization: The new dust extraction system was constructed and installed by JOA’s project managers. The implementation was carefully planned to avoid any disruption to ongoing operations, and the system was commissioned to function effectively from day one. read more about System Realization.
Outcome
The end result a redesigned extraction system for the extruder at SABIC that now works effectively, significantly reducing dust in the final product and lowering the rejection rate of valuable products. This enhancement has also contributed to the overall reliability of the plant’s machinery.
- Reduced Product Rejections: Enhanced dust control led to a significant decrease in rejected products.
- Improved Customer Satisfaction: Higher product quality resulted in fewer customer complaints.
- Increased Operational Reliability: The new system’s efficient performance minimized downtime and boosted productivity.
- Healthier Work Environment: Improved air quality contributed to a safer and more comfortable workplace for employees.
