5 ways to boost heat exchanger performance

Plate-and-shell heat exchangers have become well established in industry as a compact alternative to shell-and-tubes. However, conventional plate-and-shells are notoriously prone to fatigue that can lead to downtime in operation. This and other design limitations greatly impacts their effectiveness in production.

DuroShell, a new type of plate-and-shell heat exchanger from Alfa Laval, has been engineered specifically to overcome these challenges. If your operation is considering switching from shell-and-tubes or replacing your existing plate-and shells, here are five reasons why DuroShell makes today the right time for change:

How to minimize fatigue problems in plate-and-shell heat exchangers

Increase uptime in positions with fluctuating temperatures or pressures.

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1 Durability for increased uptime

DuroShell consists of distribution tubes running through a laser-welded plate pack. This unique internal design provides excellent resistance against the fatigue problems that plague conventional plate-and-shell heat exchangers. As a result, DuroShell can offer a longer service life with maximized uptime.

2 Robust versatility

DuroShell has been designed to fit a wide range of processes, including some of the most demanding applications in industry. The robust, unique construction handles higher operating pressures than conventional plate-and-shell designs. In fact, DuroShell can perform in duties with pressures up to 100 barg (1450 psig) or temperatures as high as 450 °C (842 °F).

3 Designed for reliability

A number of plate-and-shell designs are marketed as openable technology, which perhaps seems like an advantage. But by opening a heat exchanger, you risk creating significant problems for long-term operation and reliability. DuroShell’s closed, fully welded design ensures greater lifetime durability and improved pressure performance.

4 Even greater thermal efficiency

The patented roller coaster pattern of DuroShell’s cut-wing plates maximizes turbulence to minimize the risk of fouling. This allows for 15-20% higher thermal efficiency than other plate-and-shells, greatly reducing energy consumption over the course of the equipment’s lifecycle.

5 Opportunity for bigger savings

DuroShell offers savings on installation thanks to an even more compact and lightweight design than conventional plate-and-shell heat exchangers. This is on top of reduced energy demands and cost-effective maintenance solutions, which in turn ensure a noticeably lower total cost of ownership. These reasons and more have made DuroShell a suitable choice for a wide variety of demanding positions, particularly in the power and petrochemical industries.

Duroshell product image

Alfa Laval DuroShell RollerCoasterRollerCoaster

Robust and efficient performance


A patented plate pattern optimizes thermal efficiency with improved fatigue resistance, flow distribution and mechanical strength. 

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Alfa Laval DuroShell PowerPackPowerPack

Optimized flow distribution and fatigue resistance


Patented design enables improved fluid distribution, mechanical strength and unparalleled fatigue resistance. 

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Alfa Laval duroshell cutwingCutWing

Less weight and added reliablility


Alfa Laval's unique CutWing plates enable multipass within the shell, making the unit more compact and easier to install, since no external piping is required

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