Bitumen and heavy oil are extremely viscous (1000–100000+ cP at ambient), requiring heated handling throughout production, storage, and transport. Pumps must handle high viscosity, high temperature, abrasives (sand, solids), and maintain flow without shear degradation. This guide covers pump selection for bitumen, heavy crude, and asphalt handling.
Bitumen/Heavy Oil Process and Pump Services
| Service | Fluid | Viscosity | Temp | Key Characteristic | Pump Type |
|---|---|---|---|---|---|
| Production well (SAGD/CSS) | Bitumen + water + sand emulsion (from well) | 10000–100000+ cP (bitumen) | 150–250°C (SAGD) | Very viscous, hot, abrasive (sand), multiphase (oil/water/gas), high pressure, corrosive (H₂S, CO₂) | Progressive cavity pump (PCP, downhole, handles viscous + solids) or API 610 OH2 (surface, high temp, abrasive-resistant) |
| Wellhead transfer | Bitumen emulsion (oil + water + sand) | 5000–50000 cP | 80–180°C | Viscous, abrasive, multiphase, moderate pressure, hot, corrosive | Twin screw pump (handles multiphase, viscous, abrasive) or internal gear pump (viscous, positive displacement) |
| Storage tank transfer | Bitumen/heavy oil (heated tank) | 1000–10000 cP (at 80–120°C) | 80–150°C (heated) | Viscous, hot, settling (solids), large flow, jacketed piping, precise | Twin screw pump or internal gear pump (viscous, positive displacement, jacketed, self-priming) |
| Loading/unloading (rail/truck) | Bitumen/heavy oil (heated) | 500–5000 cP (at loading temp) | 80–150°C | Viscous, hot, precise (metered loading), intermittent, large flow, jacketed | Screw pump or internal gear pump (viscous, precise, jacketed, self-priming, flow meter) |
| Pipeline booster | Heavy crude (diluted with condensate) | 50–500 cP (diluted) | Ambient–60°C | Moderate viscosity, high pressure, large flow, continuous, abrasive (sand), corrosive | API 610 BB2 or BB3 multistage (high pressure, large flow, API 610, abrasive-resistant) |
| Refinery feed (to distillation) | Heavy crude/bitumen (preheated) | 10–500 cP (at 100–200°C) | 100–250°C | Hot, moderate viscosity, high pressure, large flow, continuous, corrosive (naphthenic acid, sulfur) | API 610 BB2 or OH2 (high temp, high pressure, API 610, alloy materials) |
| Vacuum residue (bottom of vacuum tower) | Vacuum residue (very heavy) | 1000–10000 cP (at 300–370°C) | 300–370°C | Very hot, viscous, corrosive (naphthenic acid), coking tendency, low-NPSH (vacuum), critical | API 610 OH2 (high temp alloy, low-NPSH, jacketed, centerline mounting) or BB2 (high pressure) |
| Asphalt production | Asphalt cement (AC-20, AC-30) | 1000–10000 cP (at 150°C) | 150–200°C | Viscous, hot, precise, jacketed, settling, continuous, polymer-modified (shear-sensitive) | Screw pump or internal gear pump (viscous, jacketed, precise, low shear for polymer-modified) |
| Emulsion (asphalt emulsion) | Asphalt + water + emulsifier (oil-in-water) | 100–1000 cP | Ambient–60°C | Shear-sensitive (don't break emulsion), viscous, abrasive (some), precise, moderate flow | Screw pump or rotary lobe (low shear, gentle, viscous, hygienic-ish) |
| Slop oil/water separation | Oil + water + solids emulsion | 10–1000 cP (variable) | Ambient–80°C | Variable viscosity, abrasive, corrosive (H₂S), multiphase, environmental, moderate flow | Screw pump (handles multiphase) or 316L centrifugal (corrosion-resistant) |
| Flushing (hot oil/solvent flush) | Hot gas oil or light solvent (flush lines/pumps) | 1–10 cP | 100–200°C | Hot, clean, precise, intermittent, prevents solidification | API 610 OH2 (high temp) or internal gear pump (positive displacement) |
| Wastewater (oily) | Oily wastewater (API separator feed) | 1–10 cP | Ambient–60°C | Oily, corrosive (H₂S), high COD, environmental, large flow | 316L centrifugal (corrosion-resistant, oil-resistant) |
Critical: Very Viscous + High Temperature + Jacketed
Bitumen is solid at room temperature — heating is essential throughout the system:
- Very viscous: Bitumen 10000–100000+ cP at ambient, but 100–1000 cP at 150°C. Use positive displacement pump: twin screw pump (handles 1–100000+ cP, multiphase, self-priming) or internal gear pump (1–100000 cP, simple, robust). AVOID centrifugal for ＞500 cP (can't prime, drastically reduced flow). Jacketed pump (hot oil/steam jacket, maintain 120–180°C). Jacketed piping. Heat tracing. Insulation. Pre-heat pump before startup (cold bitumen = locked rotor). Flooded suction (viscous fluid doesn't flow). Large suction lines (3–4× discharge).
- High temperature: Bitumen handled at 80–200°C, vacuum residue at 300–370°C. Use high-temp materials: carbon steel (up to 400°C), alloy steel (Cr-Mo for ＞400°C or corrosive), 316SS (corrosive service). High-temp mechanical seal (plan 32 flush, plan 53B barrier). Centerline-mounted pump (thermal expansion). Jacketed seal chamber. Thermal growth compensation. For ＞350°C: API 610 OH2 with centerline mounting, alloy casing. Our API 610/high-temp range handles hot bitumen.
- Solidification prevention: Bitumen solidifies when cool — catastrophic. Always maintain temperature (jacket + tracing). Flush with hot gas oil or solvent before shutdown (don't let bitumen sit in pump/piping). Steam-out for maintenance. Temperature alarms (below setpoint = stop pump). Strainer with steam jacket. Our jacketed range prevents solidification.
Critical: Abrasive Solids (Sand) + Multiphase
- Abrasive (sand): Heavy oil/bitumen from SAGD/CSS contains sand (0.1–5% solids). Use hardened materials: tungsten carbide or silicon carbide faces (mechanical seal), hardened 17-4PH or duplex shafts, chrome iron or duplex wetted parts. Tungsten carbide rotor/stator for screw pumps. Large passage. Flush with clean oil (seal plan 32). Monitor wear (vibration, flow drop). Strainer upstream (but sand can pass — use self-cleaning strainer). Our abrasive-resistant range handles sandy bitumen.
- Multiphase (oil + water + gas): Wellhead fluid is multiphase emulsion. Use twin screw pump (handles up to 90% gas void fraction, no emulsification damage) or progressive cavity pump (downhole). AVOID centrifugal (gas locking, reduced flow). Gas separation upstream if possible. Pressure pulsation dampener. Our twin screw range handles multiphase bitumen.
Critical: Naphthenic Acid Corrosion (High Temp Crude)
- Naphthenic acid corrosion: Heavy crudes (Venezuelan, Canadian, Russian) contain naphthenic acid (TAN ＞0.5 mg KOH/g) — corrosive at 220–400°C. Use 5% Cr-Mo steel (moderate TAN), 316SS/317SS (high TAN), or alloy 825/625 (very high TAN + sulfur). Upgrade at high-velocity areas (pump casing, impeller, seal chamber). Monitor corrosion (coupons, UT). Our alloy API 610 range handles naphthenic acid service.
- Sulfur corrosion: Sour crudes contain H₂S and mercaptans — corrosive (sulfidic corrosion at 260–480°C). Use 5Cr-0.5Mo, 9Cr-1Mo, or 316SS. NACE MR0175/ISO 15156 compliance for sour service. Stress relief. Our sour-service API 610 range handles sulfur corrosion.
Material Compatibility
| Material | Bitumen (150°C, 5000 cP, non-corrosive) | SAGD emulsion (180°C, sand, H₂S) | Vacuum residue (350°C, naphthenic acid) | Asphalt (180°C, polymer-modified) |
|---|---|---|---|---|
| Carbon steel (WCB) | Excellent (standard, up to 400°C) | Fair (H₂S + sand erosion) | NOT (naphthenic acid at 350°C) | Excellent |
| Cr-Mo alloy (5Cr, 9Cr) | Good (high temp) | Good (H₂S + temp) | Good (moderate TAN) | Good |
| 316SS/317SS | Good (overkill for non-corrosive) | Good (H₂S + corrosion) | Excellent (high TAN naphthenic) | Good |
| Duplex SS | Good | Excellent (H₂S + erosion + corrosion) | Good | Good |
| Tungsten carbide (seal faces) | Good | Excellent (sand abrasion) | Good | Good |
| Silicon carbide (seal faces) | Good | Good (abrasion, but brittle) | Excellent (corrosion + temp) | Good |
| Carbon graphite (seal faces) | Fair (low temp only) | NOT (sand + H₂S) | NOT (high temp) | Fair |
| FKM (Viton) seals | Good (up to 200°C, oil-resistant) | Fair (H₂S may affect) | NOT (＞200°C) | Good |
| FFKM (Kalrez) seals | Excellent (up to 320°C) | Excellent (H₂S + temp) | Excellent (high temp + acid) | Excellent |
| NBR seals | Fair (oil, but temp ＜100°C) | NOT (temp + H₂S) | NOT | NOT (temp) |
Critical: Bitumen (non-corrosive) = carbon steel + FKM/FFKM + screw/gear (jacketed). SAGD (sand + H₂S) = duplex/316SS + tungsten carbide + twin screw (multiphase + abrasive). Vacuum residue (350°C + naphthenic) = 316SS/317SS or alloy + FFKM + API 610 OH2 (centerline, high temp). Asphalt = carbon steel + FKM + screw/gear (jacketed, low shear for polymer). All = jacketed + heat tracing + flush (prevent solidification).
Common Problems and Solutions
Problem 1: Bitumen pump won't start (cold/solid). Bitumen solidified in pump — locked rotor. Solution: jacketed pump + jacketed piping (maintain 150°C). Pre-heat with steam/hot oil before startup. Flush with hot gas oil before shutdown. Temperature alarm. Heat tracing. Our jacketed range prevents solidification.
Problem 2: Centrifugal pump loses flow (viscous). 5000 cP bitumen — centrifugal can't handle. Solution: use twin screw pump or internal gear pump (positive displacement). Jacketed. Flooded suction. Large suction. AVOID centrifugal for ＞500 cP. Our PD range handles viscous bitumen.
Problem 3: Seal fails (sand abrasion). Sand in SAGD bitumen wears seal faces. Solution: tungsten carbide vs tungsten carbide seal faces. Seal plan 32 (clean oil flush). Hardened shaft/sleeve. Strainer upstream. Monitor wear. Our abrasive-resistant range handles sandy bitumen.
Problem 4: Vacuum residue pump cavitates (low NPSH + high temp). 350°C residue at vacuum tower bottom — very low NPSH. Solution: use low-NPSH API 610 OH2 (large eye impeller, inducer, centerline mounting). Flooded suction (mount below tower). Jacketed. High-temp seal (plan 32). Alloy materials (naphthenic acid). Our low-NPSH API 610 range handles vacuum residue.
Problem 5: Polymer-modified asphalt degrades (high shear). SBS polymer in asphalt — high shear breaks polymer chains. Solution: use screw pump (low shear) or large-passage gear pump. Low rotor speed. AVOID high-shear gear/centrifugal. Our low-shear range preserves polymer-modified asphalt.
Selection Summary
- Production (SAGD/CSS): Progressive cavity pump (downhole) or API 610 OH2 (surface, high temp, abrasive, H₂S)
- Wellhead transfer: Twin screw pump (multiphase, viscous, abrasive, self-priming) or internal gear pump
- Storage transfer: Twin screw or internal gear (viscous, jacketed, self-priming, 80–150°C)
- Loading/unloading: Screw pump or internal gear pump (viscous, precise, jacketed, flow meter, 80–150°C)
- Pipeline booster: API 610 BB2 or BB3 (high pressure, large flow, diluted crude, API 610)
- Refinery feed: API 610 BB2 or OH2 (100–250°C, high pressure, alloy, naphthenic/sulfur)
- Vacuum residue: API 610 OH2 (300–370°C, low-NPSH, centerline, alloy 316SS/317SS, FFKM, jacketed)
- Asphalt: Screw pump or internal gear pump (150–200°C, viscous, jacketed, low shear for polymer-modified)
- Asphalt emulsion: Screw pump or lobe (low shear, shear-sensitive emulsion, 100–1000 cP)
- Slop oil: Screw pump (multiphase) or 316L centrifugal (corrosion, H₂S)
- Flushing: API 610 OH2 or internal gear pump (hot gas oil, 100–200°C)
- Critical: bitumen = positive displacement (screw/gear) + jacketed + heat tracing + flush (AVOID centrifugal ＞500 cP), high temp = alloy (Cr-Mo/316SS) + FFKM + centerline mounting, sand = tungsten carbide + hardened + seal plan 32, naphthenic acid = 316SS/317SS/alloy, multiphase = twin screw, polymer-modified = low shear screw, all = API 610 for refinery + temperature control + solidification prevention
- Our screw and gear cover viscous bitumen/asphalt; API 610 OH2, BB2, BB3 cover refinery/high-pressure/high-temp. For bitumen/heavy oil pump selection, talk to our oil & gas engineers with your fluid viscosity, temperature, TAN, and solids content.