At a glance

The challenge

SABIC wanted to optimise dust extraction in the LXF plant in Bergen op Zoom to increase employee safety. In a complex chemical environment with multiple levels, explosive ATEX zones and numerous dust sources, this required an extremely detailed analysis and a solution that seamlessly integrates into the existing infrastructure.

The plan

Lybover carried out an indepth study of every step in the production process, identified all dust emission points and developed a clear principle design through a phased engineering approach. With 3D scanning and VR visualisations, the complete installation was virtually integrated, ensuring both a perfect technical fit and clear insight from the outset.

The execution

The dust extraction installation was systematically built up: from the outdoor setup with filters and fans to the main ducting, the central vacuum cleaning system, the connection of 19 extrusion lines and the optimisation of buffer vessels, LWFs and silos. The result is one integrated, fully controllable dust extraction solution that guarantees a safe working environment, perfectly tailored to SABIC’s complex chemical production context.

The Lybover Way

SABIC supports customers worldwide with advanced materials that enable the production of highquality end products. At its site in Bergen op Zoom, SABIC produces a wide range of plastic products, mainly plastic pellets. LEXAN™ resin (polycarbonate) is one of its most wellknown materials. 

The Bergen op Zoom site comprises eight manufacturing plants. The LXF plant is one of them and forms the heart of the polycarbonate production process. Located at the 200hectare industrial site in the Theodorushaven area, this plant produces a transparent, extremely impactresistant plastic used in a wide variety of applications. 

Comprehensive study for a safe working environment 
SABIC asked Lybover to optimise the dust extraction system in the LXF plant. The driver was clear: increasing employee safety. In a chemical plant with existing installations on multiple levels and an ATEX environment with explosive dust, this requires a thoughtful and highly precise approach. From day one, Lybover therefore focused on a thorough study, a clearly defined scope and a solution that is both technically robust and perfectly integrated into the existing infrastructure. 

Engineering based on indepth process knowledge 
Every step of the production process was analysed. In the LXF plant, raw materials are delivered to large silos at the top of the installation. Each silo contains a specific base material used in the recipe. From the silos, raw materials are dosed into buffer vessels. These vessels act as intermediate stations where the correct quantities of materials are combined. They need to be flexibly deployable, as SABIC works with varying recipes. The materials then move to the lossinweight feeders (LWFs). These feeders continuously measure how much material is fed into the extrusion process. Accuracy is critical: every gram too much or too little directly affects the quality of the polycarbonate. From the LWFs, the materials are transported to the extrusion lines, where they are melted, mixed and processed into the plastic pellets produced by SABIC. Dust is generated at every stage – sometimes in small quantities, sometimes more significantly – but always potentially hazardous in an ATEX environment. 

The key to this project was a deep understanding of SABIC’s process. By mapping every dust source and every detail, we were able to propose a solution that is technically solid and perfectly aligned with their complex environment.
– Sander Dewolf – Sales Engineer – AIR

From study to fully engineered project 
The project started with a complete inventory of all dust sources. Based on this analysis, Lybover developed a principle diagram, which was gradually refined into a technically substantiated and readytoorder proposal. Rather than engineering everything in one go, a deliberate choice was made to first develop one extrusion line in full detail. This approach provided both SABIC and Lybover with a clear understanding of the exact requirements and technical constraints. 

Smart engineering through 3D scanning 
Using 3D scanning, the entire solution was virtually integrated into the existing installation. This not only ensured a perfect fit, but also significantly reduced installation time on site. Thanks to VR visualisations, SABIC gained a clear view of the final result in advance. 

Thanks to our 3D scan and phased execution, we knew exactly what was possible. This allowed us to build one integrated installation in a safe and efficient way — a system SABIC can rely on from day one.
– Lieven Feijtraij – Project Engineer – AIR

Phased approach
Lybover started with the outdoor installation, supplying a robust, selfcleaning plate filter with an ultralow residual emission of < 0.1 mg/Nm³. Due to the highly explosive nature of the dust, the filter was designed fully ATEX-compliant, including rupture panels, a reinforced filter housing, special discharge valves and other safety features. 

In addition, a separate filter with blower was installed for the central vacuum cleaning system. This central vacuum system allows SABIC to safely clean up spillage and product losses. Inside the plant, various connection points were installed at strategic locations for this system. Lybover ensured the required underpressure throughout the entire plant. Here too, extremely low residual emissions of < 0.1 mg/Nm³ were achieved, fully ATEX-compliant and tailored to the specific explosive dust characteristics. Inside the plant, the main ducting was installed. SABIC handled the installation of the headers, after which Lybover carried out commissioning and finetuning.

This was followed by the phased implementation of dust extraction on the extrusion lines. In total, 19 production lines had to be connected, representing approximately 1 kilometre of stainlesssteel ducting, ranging from Ø80 to Ø1100, with a large number of small emission points. 

Other parts of the production process were also optimised: 

  • Buffer vessels: extraction can now be flexibly switched. Per group of four mixing vessels, extraction is activated only when they are in use. 
  • Lossinweight feeders: precise adjustment ensures that only excess raw material is extracted. 
  • Silos and expansion vessels: extraction was also improved here to guarantee stable and safe operation. 

This project once again demonstrates the importance of detailed engineering combined with 3D scanning. SABIC transitioned to a single, integrated, fully controllable and optimised dust extraction installation that fits seamlessly into the existing environment. 

The result:

  • a safe and healthy working environment, 
  • a solution perfectly suited to a complex chemical plant, 
  • reliable technology, combining custommade Lybover components with proven Keller filters, 
  • phased implementation without unexpected issues. 
Pleasant collaboration between Lybover and SABIC, with thoughtful input from start to finish!
– Kim van den Eijnden – Project Manager, Site Projects – SABIC

Lybover once again demonstrated how complex challenges in existing installations can be transformed into a futureproof, safe and robust solution.