What materials are suitable for heat exchange applications?

Heat exchangers are engineered to suit materials with defined thermal profiles - including minerals, aggregates, and calcined solids - by matching residence time and heat transfer requirements.

Can heat exchangers be customized for specific plant conditions?

Yes. Carrier engineers design each heat exchanger based on throughput, material behavior, and target inlet and outlet temperatures.

Bulk Material Heat Exchanger

Name: Bulk Material Heat Exchanger
Brand: Carrier Vibrating Equipment
Availability: InStock

Energy efficiency, high-quality product output, and low operational cost in a small footprint.

Reduces energy costs with highly efficient indirect heat transfer.

Prevents contamination by keeping process media separate from the material.

Handles tough materials with durable, heavy-duty construction.

Ensures uniform temperature control for consistent downstream performance.

Bulk-Flow-Heating-Cooling-Exchanger-BMHX

Indirect Heating/Cooling with Carrier’s BMHX

Carrier’s BMHX (Bulk Material Heat Exchanger) provides highly-efficient indirect bulk flow heating, cooling and conditioning of bulk solids. Since no moving parts contact the product during the heat transfer process and little to no process air is utilized, Carrier’s indirect technologies deliver a cost-effective method of heat transfer for a variety of materials. It features a gravity-fed design to flow material between thermal plates, cooling, heating, or drying the material as it works its way from top to bottom.

The product is heated or cooled when it moves across plates with water or other heat transfer fluids flowing internally through them. The product touching these plates cool by conduction, and since there is no direct contact between material and thermal fluid there is no risk of contamination or need for dust collection or scrubbers.

Request a Quote

Features & Benefits

Indirect heating/cooling design provides intimate contact between solids and plate coils for maximum efficiency. The BMHX uses gravity to move the material being processed and does not rely on large amounts of process air. Instead, the equipment uses passive temperature change through conduction, resulting in minimal energy use compared to other methods.

Counter-current fluid-to-material flow ensures even heating or cooling of bulk material solids.

Adjustable feeder on the discharge provides precise control of product flow rate and residence time.

Material moves slowly in a plug flow through the heat exchanger, reducing product degradation and preventing abrasion of the equipment. The closed environment in the bulk material heat exchanger means it can be operated consistently through different external conditions.

Little to no air exhaust eliminates the need for ancillary fans and air filtration systems in most cases. Since moving air is not used in the cooling or heating process, there is no issue with emissions or dust, making it perfect for locations or materials with strict emission regulations.

Designed to move the product vertically, the BMHX has a small footprint compared to other cooling and heating technologies which allows it to fit into existing plants with minimal retrofitting and makes it flexible to current operational requirements.

No moving parts within product contact and few ancillary components reduces maintenance costs and is easy to keep operating efficiently.

Designed for easy cleaning and part replacement means reduced downtime and expenses.

Equipment Options & Accessories

Sweep Gas System

Optional sweep gas capability to evacuate moisture or volatiles released during heating or cooling.

Aeration or Vibration

Aeration or vibration can be added to the heating/cooling tower to help sluggish materials move more freely.

Materials of Construction

Plate coils and contact surfaces can be fabricated in various materials (e.g., carbon steel, stainless steel, or other alloys) for higher temperature resistance or corrosion resistance.

PLC Control System

Optional PLC control system records and controls temperature levels and discharge rates to ensure material specifications are met.

Access Doors

Access doors provide quick access for easy cleaning and maintenance.

Applications

Biosolids

Biosolid applications involve the processing and handling of treated organic waste from municipal or industrial wastewater systems.

Catalysts

Catalyst applications involve the handling and processing of powdered, granular, or pelletized materials used to accelerate chemical reactions in industries such as petrochemicals, refining, and specialty chemicals.

Chemicals

Chemical applications involve the processing and handling of powders, granules, liquids, and other bulk materials used across a wide range of industries, including specialty chemicals, industrial chemicals, and consumer products.

Fertilizers

Fertilizer applications involve the processing and handling of granular, powdered, or pelletized materials used to improve crop yield and control weeds in agricultural and industrial markets.

Food Products

Food involves the processing and handling of raw ingredients and finished products, such as powders, granules, flakes, and particulates used in food and beverage production.

Foundry Sand

Foundry sand applications involve the handling and processing of sand used in metal casting and molding operations.

Lithium-Ion & Critical Minerals

Synthetic graphite, lithium carbonate, lithium hydroxide, NMC and LFP cathode powders, anode carbon. Closed atmosphere control critical for hygroscopic and reactive battery materials.

Metal Ore

Metal ore applications involve the handling and processing of mined metallic minerals such as iron, copper, aluminum, and other ores used in metal production, refining, and industrial processes.

Minerals

Mineral applications involve the processing and handling of raw materials and powders used in industries such as mining, ceramics, coatings, and pigments manufacturing.

Plastic Pellets

Plastic pellet applications involve the handling and processing of polymer granules used in the production of molded, extruded, or fabricated plastic products.

Proppants

Proppant applications involve the handling and processing of specialized sand, ceramic, or resin-coated materials used in hydraulic fracturing to keep fractures in oil and gas wells open.

Salt

Salt applications involve the processing and handling of crystalline, granular, or powdered salts used in chemical manufacturing, water treatment, food processing, and other industrial applications.

Sand

Sand applications involve the handling and processing of natural or manufactured sand used in industries such as construction, glass production, foundries, and hydraulic fracturing.

Featured Resources

When an innovative manufacturer sought to expand into international markets, export regulations created a critical processing challenge. Carrier Vibrating Equipment evaluated multiple technologies and engineered a customized thermal processing solution that met stringent heat-treatment requirements while preserving product quality and production efficiency. Download the case study to learn how Carrier helped enable global market access, support business growth, and deliver a reliable long-term processing solution.

Download Case Study

Brochures

Bulk Material Heat Exchanger Brochure

Carrier Capabilities Brochure

CPEG Capabilities Brochure

Gallery

Bulk Material Heat Exchanger FAQs

What is indirect bulk solids heat exchange?

Bulk solid material flows downward by gravity through a vertical array of hollow plates. A thermal fluid – water, steam, oil, or gas – circulates inside the plates and transfers heat through conduction directly into or out of the bulk solid. The product and thermal fluid never come into contact, and no process air passes through the material.

What thermal fluids can be used?

The BMHX operates with cooling water, chilled water, hot water, propylene glycol, ethylene glycol, steam, or thermal oil depending on the application and required temperatures. Carrier’s test facility can evaluate performance with water, heating oil, or steam.

Why eliminate process air from the heat transfer step?

Conventional direct-contact systems require large air volumes, high fan horsepower, baghouses, scrubbers, and emission permits. Eliminating air removes particulate and VOC-laden exhaust, reduces energy loss, and simplifies compliance. For reactive, temperature-sensitive, or dust-generating materials, avoiding air contact also prevents oxidation, contamination, and the risk of combustible dust ignition.

Does the BMHX generate process exhaust that requires permitting?

No product-laden exhaust air is generated by the heat exchange step itself. Conventional direct-contact systems generate large volumes of product-laden air requiring baghouses, scrubbers, or thermal oxidizers with associated capital cost, operating cost, and permitting obligations. The BMHX eliminates this exhaust stream from the heat transfer step.

Can it run under an inert atmosphere?

Yes. Because no process air contacts the product in the heat-exchange section, the unit is inherently suited for oxidation-sensitive, hygroscopic, or contamination-sensitive materials. For applications requiring strict atmosphere control, the housing can be configured for inert gas purge.

What if my material isn’t free-flowing?

For materials that don’t flow freely through the plate array, vibration and/or small amounts of gas flow can be added to assist mass flow through the unit. This is evaluated during test runs at Carrier’s Louisville facility.

How does a bulk material heat exchanger improve thermal efficiency?

It transfers heat directly between hot and cold bulk materials without intermediate fluids, improving energy efficiency and reducing fuel use.

What does a test run at Carrier’s laboratory determine?

A properly conducted test run determines: (1) an energy balance yielding heat duty under test conditions; (2) the effective overall heat transfer coefficient (U) for your specific material – the core parameter driving full-scale surface area calculation; and (3) material handling behavior: flow reliability through the plate array, bridging tendency, segregation, packing, and particle degradation at operating temperatures. These observations inform the selection of plate spacing and the design of the discharge feeder in the full-scale unit.

How do heat exchangers integrate with dryers or coolers?

They can be placed upstream or downstream of thermal systems to preheat feeds or recover heat from processed solids, improving overall plant energy performance.

What maintenance should I expect?

Maintenance focuses on inspecting wear surfaces and airflow paths, which are designed to be accessible for routine checks.

Can the heat exchanger be customized for my process?

Carrier customizes tube geometry, flow patterns, discharge controls, jackets, and medium circuits to match your material and cooling/heating needs.