The Heart of the BITUMEN HEATER : A Tailored Heat Exchanger

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In designing a bitumen heating system, the heat exchanger must be carefully matched to the properties of the fluid.  Key data inputs in the design process include:

  • Viscosity at different temperatures: Bitumen’s viscosity can vary by orders of magnitude between 60°C and 180°C. The system must deliver enough heat to reach and maintain the target temperature range while ensuring laminar-to-turbulent flow transitions are well-managed.
  • Flow rate: The required throughput (e.g., liters per minute) affects the heat exchanger sizing, pressure drop, and heating time. Undersizing can result in poor heating performance, while oversizing increases cost and footprint unnecessarily.
  • Temperature differential: Designing for a small ΔT (temperature difference) between the heating medium and the bitumen requires more surface area and higher flow turbulence to ensure efficient heat transfer.

In this project, we customized the shell-and-tube heat exchanger configuration, selecting materials with high thermal conductivity and durability. We also designed the internal baffling system to maximize turbulence in the bitumen side without causing excessive pressure drop—ensuring efficient heating and reliable operation over time.

Every unit we produce is subjected to rigorous quality checks, hydrostatic testing, and thermal simulation analysis to ensure it meets performance expectations under real operating conditions.