Our client in Malaysia, a leading road construction materials provider, faced persistent challenges in measuring high-viscosity bitumen during their blending process. Bitumen’s density and viscosity change rapidly with temperature, making traditional volumetric flow meters highly unreliable.
Case Details
Our client in Malaysia, a leading road construction materials provider, faced persistent challenges in measuring high-viscosity bitumen during their blending process. Bitumen’s density and viscosity change rapidly with temperature, making traditional volumetric flow meters highly unreliable.
❌ The Challenge
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Severe Inaccuracy: The existing volumetric meters showed a measurement error of 1.5%, leading to material waste and inconsistent product quality.
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High Maintenance: Mechanical parts were frequently clogged by the cooling bitumen, causing costly downtime.
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Extreme Conditions: The fluid temperature exceeded 160°C, requiring sensors with high thermal stability and reliability.
✅ Hanyu’s Technical Solution
After a comprehensive site analysis, Hanyu’s technical team recommended a
High-Precision Coriolis Mass Flow Meter with a specialized heat jacket. Unlike volumetric meters, Coriolis technology measures mass directly, which is unaffected by changes in viscosity or density.
Key Sourcing Strategy:
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Material Selection: Using high-grade 316L or Hastelloy sensors to withstand the abrasive nature of impure bitumen.
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Thermal Management: Integrated heat tracing to ensure the bitumen remains fluid inside the sensor tubes.
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Digital Integration: RS485/Modbus RTU output for real-time monitoring and automated batch control.
🚀 The Result
Within three months of installation, the client reported transformative improvements:
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Accuracy Boost: Measurement error dropped from 1.5% to 0.1%.
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Zero Downtime: The non-intrusive design eliminated clogging issues, reducing maintenance costs by 80%.
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ROI Realized: The project paid for itself within 6 months through material savings and improved throughput.
💬 Client Testimonial
"Hanyu didn't just sell us a meter; they provided the expertise to solve a decade-long problem. Their selection for our bitumen process has achieved 0.1% precision, something we thought was impossible in these conditions." — Plant Engineering Manager, Malaysia
Key Technical Insights (FAQ)
Why is a Coriolis meter better than an ultrasonic meter for bitumen?
Bitumen is highly viscous and often contains temperature-induced density changes. Coriolis meters measure mass directly via inertia, providing stable 0.1% accuracy. Ultrasonic meters, however, rely on sound waves which are easily weakened (attenuated) by thick, non-homogeneous fluids.
What specific results were achieved in this Malaysia project?
By switching to the Hanyu-sourced Coriolis solution, the client successfully reduced measurement error from 1.5% to 0.1%. Additionally, the non-intrusive sensor design eliminated clogging, resulting in an 80% reduction in annual maintenance costs.
Does Hanyu offer support for specialized material selection?
Yes. As a technical sourcing expert, Hanyu provides sensors in high-grade alloys such as Hastelloy C22, Titanium, and Tantalum. Our team performs a material compatibility analysis for each corrosive environment to ensure maximum sensor lifespan.
