Steel-Alum Extruded Finned Tubes for Pakistan Paper Mill

Client Success Story: Powering Efficient Drying for a Pakistan Paper Mill

Our client operates a large-scale paper manufacturing plant in Pakistan. In paper production,operating multiple advanced production lines for corrugated paper and containerboard,the drying process requires massive amounts of heat exchange,the steam heat exchange efficiency in the drying section directly dictates both the output and quality of the paper, The plant had been using traditional wrapped finned tubes in their air preheaters and steam air heaters.

However, they faced severe operational bottlenecks:

• Rapid Corrosion: The highly humid and corrosive environment in the paper mill caused moisture to penetrate the gaps between the base tube and fins.

• Thermal Resistance Increase: As corrosion progressed, the fins loosened, leading to a sharp drop in heat transfer efficiency.

• Frequent Downtime: The plant had to shut down for maintenance every few months to replace failed tubes, severely hurting production output and escalating labor costs.

• Declining Heat Exchange Efficiency: The original plain tube or wrapped finned tube radiators had high contact thermal resistance and failed to provide sufficient steam heat. This resulted in incomplete drying of the paper sheets, severely limiting machine speed.

• Poor Condensate Drainage: Uneven heat exchange caused water hammer phenomena within the system, generating loud noises and shortening equipment lifespan.

• High Energy Costs: To maintain production temperatures, the plant was forced to increase steam supply, leading to skyrocketing monthly energy bills.

The Datang Solution: Steel-Aluminum Extruded Finned Tubes

After analyzing the client’s technical drawings and environmental data, the engineering team at Datang Finned Tube proposed a transition to Steel-Aluminum Bimetallic Extruded Finned Tubes (Base Tube: Carbon Steel / Fin: Aluminum).

Unlike traditional tubes, Datang’s extruded finned tubes feature a unique manufacturing process: the outer aluminum tube is hydraulically extruded onto the inner steel tube under high pressure.

Traditional Wrapped Tube –> Gaps open up –> Moisture enters –> Corrosion & Efficiency Loss
Datang Extruded Tube–> 100% Tight Bond –> Zero Gaps –> Maximum Heat Transfer & Longevity

• Zero Contact Thermal Resistance: Utilizing an advanced cold extrusion process, the aluminum tube is tightly extruded onto the steel base tube. This ensures 100% contact between the fin and the base tube, completely eliminating the contact thermal resistance common in traditional L-footed or wound finned tubes.
• Exceptional Heat Transfer Efficiency: The excellent thermal conductivity of aluminum, combined with the tight bonding process, allows these tubes to deliver significantly higher heat output in a smaller footprint compared to traditional radiators.
• Corrosion Resistance & Durability: The extrusion process creates a smooth, dense aluminum fin surface that effectively resists corrosion in the humid environment of a paper mill. Additionally, the fins remain secure and do not deform easily.

Why this was the perfect fit for the Pakistan Paper Mill:

1. Complete Corrosion Isolation: The outer aluminum layer forms a seamless, continuous sheath over the inner steel tube, completely blocking the humid paper mill air from corroding the core tube.

2. Permanent Thermal Contact: Even under continuous high-temperature thermal cycling, the tight mechanical bond ensures zero air gaps, maintaining optimal thermal conductivity.

3. High Rigidity: The robust extruded aluminum fins can withstand high-pressure washing during routine maintenance without bending or deforming.

Measuring total outer diameter of Datang steel-aluminum extruded finned tube for Pakistan paper mill

Wall thickness measurement of carbon steel base tube for Datang bimetallic finned tube project

Checking precise fin pitch and spacing of extruded finned tube to optimize paper mill heat exchanger efficiency

Measuring bare tube ends length of Datang extruded bimetallic finned tubes before welding installation

Inspecting aluminum fin height accuracy of Datang extruded fin tubes for high-humidity paper manufacturing plant

The Results & Customer Testimonial

After installing Datang’s extruded finned tubes, the Pakistan paper mill monitored the performance over a 12-month period. The upgrades delivered measurable financial and operational success:

• +25% Heat Transfer Efficiency: The air preheater achieved much higher thermal efficiency, significantly reducing steam consumption.The drying section responded much faster to temperature changes, significantly improving steam utilization and eliminating drying bottlenecks.

• Zero Unscheduled Downtime: Not a single finned tube failed during the first year of continuous operation.

• 60% Reduction in Maintenance Costs: The durable structure eliminated the need for frequent part replacements.

• Increased Production Capacity: With a stable and ample heat supply, the paper machine speed was increased, boosting overall daily production by approximately 15%

• Energy Savings: Steam consumption dropped by about 20% for the same output level. The client recovered the total cost of the retrofit within just 8 months of operation.

Client Feedback: “We were skeptical about switching tube types at first, but Datang Finned Tube provided exceptional technical support and a world-class product. Our energy bills have dropped significantly, and the equipment is running smoother than ever. Datang is now our strategic partner for all future heat exchanger upgrades.” — Production Director, Pakistan Paper Mill

Looking for Efficient and Reliable Heat Exchange Solutions?
Whether you are in the power, chemical, textile, or paper industry, Datang Finned Tube provides custom finned tube solutions tailored to your needs.