Overview
When Vesenergy faced the challenge of upgrading an outdated heat exchanger at one of their asphalt processing plants, they partnered with KAM Thermal Equipment for a custom-engineered solution. The result: a dramatic boost in output temperatures, faster batch production, and seamless installation without major modifications—delivered through expert remote collaboration and precision engineering.About Vesenergy
Vesenergy operates in the asphalt manufacturing industry, specializing in the production of polymerized asphalt products. Precision thermal control is critical in their facilities, where heating asphalt to exact target temperatures ensures product quality and process efficiency.
The Challenge: Outdated Equipment Holding Back Production
The plant’s original heat exchanger, built decades earlier, was not designed to handle the demands of modern polymerized asphalt production. It struggled to deliver the required thermal output, impacting the efficiency of Vesenergy’s processes.
Their polymerized asphalt production process required heating the asphalt to at least 300°F—a target the old heat exchanger could not consistently achieve. Even when pushed, the system only reached about 320°F, short of the optimal range for efficient polymerization.
Key limitations of the old unit:
- Could only raise process temperature to around 320°F, well below the required 380°F.
- Originally designed for regular asphalt storage, not polymerized materials.
- Underused due to poor suitability for new production demands.
- Located in a tight space with fixed saddles and concrete footings, making standard replacements impractical.
The Risks of Inaction
Had Vesenergy continued operating with the outdated exchanger, they would have faced:
- Extended production times, slowing down daily operations.
- Reduced batch throughput, limiting plant profitability.
- Inefficient energy use, driving up operational costs.
- Potential product quality issues due to inconsistent process temperatures.
"It was strictly time. We were losing time to produce the product."
The Solution: A Custom-Engineered Heat Exchanger from KAM Thermal Equipment
Recognizing the complexity of the project, KAM Thermal Equipment collaborated closely with Vesenergy to design a fully custom shell and tube heat exchanger that fit perfectly into the plant’s existing footprint—avoiding costly rework.
Key features of KAM’s solution:
- Custom footprint to match existing saddles and support structures.
- Thermal design optimization to maximize heat transfer efficiency without altering the hot oil system (fixed at 425°F).
- Remote collaboration, with detailed measurement exchanges and design drawings handled without the need for onsite visits.
- Faster turnaround, with the unit designed, built, and delivered in approximately 3 months after final drawings were approved.
“They did the thermal work, designed it to fit our old saddles, and made sure everything lined up perfectly. It was a pleasure working with them.”
The Results: Major Performance Gains and Operational Impact
✅ Output Temperature Boosted by ~60°F
Previous output: ~320°F
New output: nearly 380°F
Enabled immediate start of the asphalt polymerization process, eliminating inefficient workaround heating methods.
✅ Significant Increase in Daily Production
Vesenergy was able to produce two additional full batches per day after installation.
Faster process startup translated directly into higher throughput and profitability.
✅ Zero Infrastructure Rework Needed
The new exchanger fit precisely into the existing concrete supports and piping layout.
No costly field modifications, major downtime, or installation delays.
✅ Remote Engineering Success
Project delivered entirely through remote collaboration and technical design exchange.
Minimized project cost and complexity despite the plant’s physical constraints.
✅ High Customer Satisfaction
Vesenergy praised KAM’s responsiveness, attention to detail, and hands-on support during the design and manufacturing phases.
"They were always available when we had questions or needed to tweak something."
Timeline
- Initial contact to installed solution: ~6 months total.
- Custom fabrication after final design: ~3 months.
Why Choosing the Right Heat Exchanger Matters
A poorly sized or outdated heat exchanger can cripple plant performance, leading to:
- Lower throughput
- Higher energy costs
- Inconsistent product quality
- Lost revenue opportunities
KAM Thermal Equipment’s expert thermal design ensured Vesenergy didn’t just replace an old unit—they upgraded to a more efficient, profitable, and future-proof system.
About KAM Thermal Equipment
KAM Thermal Equipment is a 4th-generation, family-owned manufacturer of custom shell and tube heat exchangers and tube bundle replacements. Proudly made in the USA and fully compliant with ASME Section VIII, Division 1 and TEMA standards, KAM delivers precision-engineered thermal solutions that meet the highest demands of industries like oil & gas, asphalt processing, power generation, and chemicals.
When downtime isn’t an option, trust KAM Thermal Equipment to deliver the right solution—custom built, expertly engineered, and backed by more than a century of experience.
📞 Need a Custom Heat Exchanger Solution?
Visit kamthermal.com or call (631) 348-4800 to speak with our engineering team today.