Alfa Laval DuroShell is a specially engineered plate-and-shell heat exchanger ideal for demanding duties and corrosive media. Able to withstand fatigue even at high temperatures and pressures, DuroShell outperforms not only traditional heat exchangers, but also conventional plate-and-shell designs.

DuroShell vertical product image

Benefits

  • More uptime and longer life due to greater fatigue resistance
  • Higher operating pressures thanks to robust, patented construction
  • Operational gains created by 15–20 % higher thermal efficiency
  • Installation savings through even more compact, lightweight design
  • Greater reliability as a result of closed, fully welded construction

The compact Alfa Laval DuroShell plate-and-shell heat exchanger offers exceptional thermal performance and fatigue resistance. Designed for use with liquids, gases and two-phase mixtures at pressures up to 100 bar (1450 psi), in both PED and ASME, and at temperatures up to 450°C (842°F), DuroShell is suitable for a wide range of aggressive media.

Industries

Petrochemical industry

Heat exchangers are used in a wide range of demanding positions in the petrochemical industry. They meet the challenges that shell-and-tube and conventional plate-and-shell designs have problems with.

Power industry

Shell-and-tube heat exchangers have long been used in demanding positions gasketed plate heat exchangers can’t manage. But space is a scarce resource in power plants. Bulky shell-and-tubes require a lot of it as well as a large capital investment.

Marine industry

Compact performance for the toughest demands – Alfa Laval DuroShell for marine thermal applications.

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Meet our experts

PowerPack for optimized flow distribution and fatigue resistance

RollerCoaster for robust and efficient performance

Cut-Wing plates for less weight and added reliability

Maximize uptime

Cut costs

Increase capacity

Plate-and-shell made tougher

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Improving sustainability

How it works

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Robust, flexible, efficient

DuroShell's robust design minimizes maintenance and maximizes uptime. The patented roller coaster plate pattern ensures exceptionally high thermal efficiency, while unique cut-wing plates allow for multi-pass design. The fully welded design allows for high operating pressure and optimizes resistance to fatigue. Distribution pipes run through the plate pack, relieving stress on the pack itself.

DuroShell is a plate-and-shell heat exchanger with a groundbreaking internal design that offers improved efficiency and durability to maximize uptime, cut costs and increase production capacity.

Revolutionary technology

DuroShell's laser-welded plate pack comprises cut-wing plates and plates pressed with a patented roller coaster pattern that resists fatigue.

The distribution tubes run through the plate pack on the plate side to further increase strength.

The roller coaster pattern improves thermal efficiency by maximizing turbulence and minimizing fouling. The cut-wing plate design creates an open area on each side of the shell interior, allowing multi-pass arrangements for even greater efficiency.

Alfa Laval DuroShell plate and shell heat exchanger exploded view

 

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Resistance to fatigue

DuroShell withstands large variations in temperature and pressure, unlike conventional plate-and-shell heat exchangers.

Corrugated plates tend to expand in just one dimension. DuroShell plates expand evenly in all directions thanks to their patented roller coaster pattern. No weak spots arise under stress means better resistance to thermal and pressure fatigue.

The entire plate pack is reinforced by the distribution tubes, removing vibrations due to flow turbulence or phase change.

Laser welding is used throughout, creating the most accurate weld with the least heat stress on surrounding material, further improving fatigue resistance.

The interior of a duroshell heat exchanger

Optimized flow

DuroShell operates with one media on the plate side and the other on the shell side. Both can be rated up to the full 100 barg (1450 psig).

In a single-pass configuration the heat exchanger works in pure cross-flow. In a multi-pass arrangement the flow is equivalent to a global counter-current configuration.

Distribution tubes extend through the plate pack to ensure even distribution of media across the heat transfer surface. Since the nozzles on the shell side are independent from those on the plate side, DuroShell is ideal for asymmetric flow duties.

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Case stories

Improved product quality and process yield

Green chemicals plant replaced failed heat exchanger with DuroShell, offering fatigue resistance up to 5 times higher than other plate-and-shell heat exchangers

Secured uptime in coal tar oil depot

High resistance to material fatigue, outstanding thermal efficiency, minimal fouling and a well-developed service network were the major reasons for Rütgers to install two Alfa Laval DuroShell heat exchangers.

Maximized uptime and reduced costs

More uptime, reduced energy costs and better compliance with environmental regulations for the Swedish renewable energy company.

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Unique features

DuroShell gives you compact performance for the toughest demands. It derives its uniqueness from our patented innovations, based on decades of experience in thermal transfer. Combined, these features lead to more reliable and efficient performance, helping you to save energy and improve your sustainability. 

 

PowerPack™

Optimized flow distribution and fatigue resistance

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

Find out more

RollerCoaster™

Robust and efficient performance

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

Find out more

CutWing™

Less weight and added reliability

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

Find out more

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Talk to an expert

We will be happy to discuss the benefits a DuroShell can bring you and show how we can help improve your operation.

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