A Hybrid Baffle Approach for Reducing Pressure Drop without Compromising Heat Transfer in Shell Side Flow of Heat Exchangers

The Shell and tube heat exchangers are widely used in thermal systems, and the configuration of internal baffles significantly influences their thermal and hydraulic performance. Traditional segmental baffles while enhancing heat transfer through turbulent flow, contribute to a substantial pressure drop. Conversely, inclined baffles offer smoother flow paths and reduced pressure losses but may underperform in turbulence generation. This dissertation proposes and investigates a novel hybrid baffle configuration combining inclined and segmental baffles to achieve the best of both designs. The objective is to reduce excessive pressure drop associated with conventional segmental baffles while maintaining or improving the heat transfer coefficient. Computational Fluid Dynamics (CFD) simulations and theoretical models are utilized to compare the thermal performance, pressure drop, and flow characteristics across various baffle arrangements. The results demonstrate that the hybrid baffle design achieves a balanced enhancement in heat exchanger performance, providing insights into effective heat exchanger design with practical relevance to industries.