Shell-side pressure drop comparison: in a shell-and-tube exchanger, which baffle type typically produces the highest shell-side pressure drop for a given duty?

Introduction / Context:
Baffles control shell-side crossflow, heat-transfer coefficient, and tube support. The choice of baffle affects pressure drop, fouling tendency, and vibration. Knowing which baffle produces the highest pressure drop helps balance thermal and hydraulic design targets.

Given Data / Assumptions:

• Comparable shell size and tube bundle; same heat duty and flow rate.
• Single-phase shell-side flow.
• Typical cut and spacing practices for each baffle type.

Concept / Approach:
Segmental baffles force fluid to repeatedly cross the tube bundle at right angles, creating strong crossflow and high turbulence. This enhances heat transfer but also produces higher pressure drop relative to designs that permit more longitudinal flow (e.g., disk-and-ring, orifice, or helical baffles).

Step-by-Step Solution:
Compare flow patterns: segmental → strong crossflow; disk-and-ring → alternating annular passages; orifice → partial crossflow; helical → continuous spiral, lower pressure drop.For the same duty, segmental baffles yield the highest shell-side ΔP in most standard configurations.Therefore, the baffle type with maximum ΔP is single-segmental.

Verification / Alternative check:
Thermal rating correlations show segmental baffles achieve high shell-side h at the cost of ΔP, while helical and disk-and-ring reduce ΔP for similar duty.

Why Other Options Are Wrong:
(a), (c), and (e) provide lower ΔP for equivalent conditions. (d) is incorrect because baffle type strongly influences hydraulics.

Common Pitfalls:
Ignoring vibration support requirements when reducing ΔP; using identical spacing/cuts across types without re-rating.

Final Answer:
Single-segmental baffles