The ABS plant of the client, a significant petrochemical producer, is designed to produce 600,000 tonnes of ABS resin annually. This facility is one of the country's major ABS resin production bases. The line employs a variety of mid-to-large co-rotating twin-screw pelletizing systems, with machine sizes ranging from Φ58 mm to Φ177 mm. These systems are capable of conducting melt homogenization, mixing, devolatilization, and pelletizing. The customer desired a spare-parts system that was more stable and reliable after years of operation. This system would involve the OEM replacement of core components, which would maintain the stability of the equipment and the consistency of the product, while simultaneously reducing the total procurement and maintenance costs.
ABS Compounding for a Major Petrochemical Producer
Twin-Screw Extruder Screw
Customer Challenges
The production of ABS is a continuous process industry, necessitating exceptional reliability from the twin-screw system as equipment operates under sustained high load. The customer sought to eliminate the need for a single-OEM parts system and establish a unified supply platform that encompassed the entire equipment range, thereby reducing the cost of procurement and maintenance. This platform would apply to a variety of machine sizes.
Simultaneously, they established near-OEM compatibility standards for the replacement components. The assembly quality and running stability are directly influenced by the spline precision, length accuracy, outer-diameter dimensions, and intermeshing profile of the screw elements, particularly on the large Φ133 mm and Φ177 mm units. Each replacement component was required to be directly interchangeable with the original system and maintain long-term stability without affecting the current process conditions.
Our Solution
Lesun established a professional technical team to rigorously measure and analyze the customer’s existing equipment and designed a replacement-development program for the entire Φ58–Φ177 mm range. The original equipment parameters of the database were obtained by a thorough validation of important structural dimensions and operational circumstances.
The project aimed at managing the spline structure, element length, intermeshing profile, and essential fit parameters to achieve stable interchange with the original system in terms of assembly precision and running performance for all sizes. Material solutions optimized for working circumstances of ABS were found to be able to meet long-cycle running, with better total cost of usage.
Project Execution
Lesun provided technical support throughout the entire process, from the commencement of the project to the commissioning phase.
- Early stage: on-site measurement and equipment-data confirmation, with systematic verification of critical dimensions to give an accurate basis for design.
- Manufacturing stage: strict process control and quality inspection, with full-process monitoring of critical dimensions to meet the precision and consistency demands of large twin-screw systems.
- Delivery stage: the technical team supported installation verification and operational tracking, ensuring each size was replaced and brought into production smoothly.
The project supplied replacement parts for the full range of machine sizes and established a unified spare-parts system for the ABS production line.
Project Outcome
After being placed into service, each twin-screw unit operated consistently and closely resembled the original equipment. The customer reported that the assembly process was seamless and efficient, as all elements were installed directly without the need for secondary refitting or structural adjustments. There was no abnormal vibration or running fluctuations, and the critical process parameters (temperature, pressure, and torque) remained constant after start-up. The parts demonstrated exceptional mechanical reliability and process adaptability during prolonged operation, thereby meeting the continuous production needs of a substantial petrochemical facility. Additionally, the customer's procurement efficiency and inventory management were significantly enhanced by the unified supply system.
Project Value
This project demonstrated Lesun's engineering expertise in large-scale petrochemical polymer equipment, as well as its technical strength in domestic replacement for mid-to-large twin-screw extrusion systems. The replacement procedure involved rigorous benchmarking of dimensional precision, assembly compatibility, running stability, and process consistency. The Φ133-Φ177 mm big sizes required high manufacturing and quality control standards. The project successfully replaced the entire Φ58-Φ177 mm platform, demonstrating Lesun's ability to develop and manufacture core parts for large twin-screw systems and provide OEM-compatible replacement solutions for petrochemical polymers and modified materials.