Client: Saudi Methacrylates Company (SAMAC – SABIC / Mitsubishi Chemical JV)
Location: Jubail Industrial City, Kingdom of Saudi Arabia
Facility Unit: Polymethyl Methacrylate (PMMA) Resin Plant
Equipment: High-Torque Co-Rotating Twin-Screw Extruder, Melt Pump Assembly & Underwater Pelletizer
Services: High-Precision Extruder Overhaul, Barrel Segment Alignment, Screw Element Reconditioning, Die Plate Resurfacing
Project Overview
SMH Arabia completed a full-scope mechanical overhaul of the primary PMMA pelletizing extruder train during a planned unit outage at SAMAC’s acrylic resin manufacturing complex in Jubail. To eliminate polymer contamination, barrel scoring, and melt-pressure fluctuations, the engineering team executed complete disassembly, dimensional metrology, and precision field alignment across the twin-screw extruder barrel, melt pump, cutter head assembly, and drive motor.
Core Engineering & Mechanical Scope
- Extruder Barrel & Screw Element Overhaul: Extraction of twin-screw shafts, non-destructive testing (LPI/MPI) for thermal stress micro-cracks, screw segment re-configuration, and bimetallic barrel liner bore measurement.
- Melt Pump & Cutter Head Refurbishment: Complete mechanical servicing of high-pressure polymer melt gear pumps, replacement of high-temperature mechanical seals, cutter hub re-balancing, and precision die plate face resurfacing.
- Extruder Drive Gearbox Servicing: Gear tooth contact pattern analysis (backlash checking), internal bearing replacement, shaft oil seal renewal, and lube oil flushing.
- Laser Shaft Alignment & Metrology: High-precision laser alignment across the main motor, heavy gearbox, melt pump, and extruder drive shaft to correct thermal growth offsets.
- Pre-Commissioning & Dynamic Testing: Cold/hot runout checks, uncoupled solo motor runs, baseline vibration monitoring, and dynamic balancing of rotating cutter assemblies at the SMH central workshop.
Key Outcomes & SEO Highlights
On-Time Outage Delivery: Executed full mechanical refurbishment strictly within SAMAC’s scheduled shutdown window under ISO 9001, 14001, and 45001 compliance.
Resin Melt Quality & Flow Rate: Restored steady melt-pressure delivery, eliminating melt fracture and ensuring uniform PMMA pellet size.
Mechanical Integrity: Reduced drive train vibration levels well within original OEM baseline limits.