Investigation of the effects of binary hybrid nanofluids and different arrangements of corrugated tubes on thermal performance

Abstract

This research examined the effects of corrugation distance and nanofluid volume concentration on pressure drop, Nusselt number, and thermal performance in a circular tube. Binary nanofluid (MWCNT/Al₂O₃, 60:40) with volume fractions of 0.25%, 0.5%, and 1% was tested in corrugated tubes with distances of 10 mm, 20 mm, and 30 mm under constant heat flux (20 kW/m²) for Reynolds numbers between 10,000 and 40,000. 3D single-phase model using ANSYS 19 with the standard k-ε turbulence model was employed and validated against literature equations. Results revealed that heat transfer improved with increasing Reynolds number, primarily due to elevated flow rates and intensified mixing induced by the corrugated surfaces. Compared to smooth tubes, the corrugated tubes exhibited higher Nusselt numbers, signifying better convective heat transfer performance. Nonetheless, this improvement was accompanied by increased friction factors and pressure drops, especially at shorter corrugation distances. Shorter corrugation distances intensified turbulence and mixing, enhancing heat transfer, while longer distances diminished turbulence, lowering the Nusselt number. The optimal thermal performance, with a performance evaluation criterion of 1.27, was achieved at a corrugate distance of 10 mm and MWCNT/Al₂O₃ nanofluid concentration of 1%. This research highlights the influence of corrugate distance on the thermal efficiency of corrugated tubes.

Keywords

• Binary nanofluid
• Corrugated tube
• Heat transfer
• Performance Evaluation Criteria
• Pressure drop

References

1. Kalendar, A., Galal, T., Al-Saftawi, A. and Zedan, M. (2011) Enhanced tubing thermal performance for innovative MSF system. Journal of Mechanical Science and Technology, 25, 1969–77. https://doi.org/10.1007/s12206-011-0524-7
2. Kareem, Z.S., Mohd Jaafar, M.N., Lazim, T.M., Abdullah, S. and Abdulwahid, A.F. (2015) Passive heat transfer enhancement review in corrugation. Experimental Thermal and Fluid Science, Elsevier Inc. 68, 22–38. https://doi.org/10.1016/j.expthermflusci.2015.04.012
3. Van Cauwenberge, D.J., Dedeyne, J.N., Van Geem, K.M., Marin, G.B. and Floré, J. (2018) Numerical and experimental evaluation of heat transfer in helically corrugated tubes. AIChE Journal, 64, 1702–13. https://doi.org/10.1002/aic.16038
4. Andrade, F., Moita, A.S., Nikulin, A., Moreira, A.L.N. and Santos, H. (2019) Experimental investigation on heat transfer and pressure drop of internal flow in corrugated tubes. International Journal of Heat and Mass Transfer, Elsevier Ltd. 140, 940–55. https://doi.org/10.1016/j.ijheatmasstransfer.2019.06.025
5. Navickaitė, K., Cattani, L., Bahl, C.R.H. and Engelbrecht, K. (2019) Elliptical double corrugated tubes for enhanced heat transfer. International Journal of Heat and Mass Transfer, 128, 363–77. https://doi.org/10.1016/j.ijheatmasstransfer.2018.09.003
6. Wang, G., Qi, C., Liu, M., Li, C., Yan, Y. and Liang, L. (2019) Effect of corrugation pitch on thermo-hydraulic performance of nanofluids in corrugated tubes of heat exchanger system based on exergy efficiency. Energy Conversion and Management, 186, 51–65. https://doi.org/10.1016/j.enconman.2019.02.046
7. Ekiciler, R. (2024) Analysis and Evaluation of the Effects of Uniform and Non-uniform Wall Corrugation in a Pipe Filled with Ternary Hybrid Nanofluid. Arabian Journal for Science and Engineering, Springer Berlin Heidelberg. 49, 2681–94. https://doi.org/10.1007/s13369-023-08459-4
8. Ajeel, R.K., Saiful-Islam, W., Sopian, K. and Yusoff, M.Z. (2020) Analysis of thermal-hydraulic performance and flow structures of nanofluids across various corrugated channels: An experimental and numerical study. Thermal Science and Engineering Progress, 19. https://doi.org/10.1016/j.tsep.2020.100604

9. Wang, W., Zhang, Y., Lee, K.S. and Li, B. (2019) Optimal design of a double pipe heat exchanger based on the outward helically corrugated tube. International Journal of Heat and Mass Transfer, Elsevier Ltd. 135, 706–16. https://doi.org/10.1016/j.ijheatmasstransfer.2019.01.115
10. Wang, W., Zhang, Y., Li, B. and Li, Y. (2018) Numerical investigation of tube-side fully developed turbulent flow and heat transfer in outward corrugated tubes. International Journal of Heat and Mass Transfer, Elsevier Ltd. 116, 115–26. https://doi.org/10.1016/j.ijheatmasstransfer.2017.09.003
11. Wang, W., Zhang, Y., Liu, J., Li, B. and Sundén, B. (2018) Numerical investigation of entropy generation of turbulent flow in a novel outward corrugated tube. International Journal of Heat and Mass Transfer, Elsevier Ltd. 126, 836–47. https://doi.org/10.1016/j.ijheatmasstransfer.2018.06.017
12. Wang, W., Zhang, Y., Li, Y., Han, H. and Li, B. (2018) Multi-objective optimization of turbulent heat transfer flow in novel outward helically corrugated tubes. Applied Thermal Engineering, Elsevier Ltd. 138, 795–806. https://doi.org/10.1016/j.applthermaleng.2017.12.080
13. Oflaz, F., Keklikcioglu, O. and Ozceyhan, V. (2022) Investigating thermal performance of combined use of SiO2-water nanofluid and newly designed conical wire inserts. Case Studies in Thermal Engineering, Elsevier Ltd. 38, 102378. https://doi.org/10.1016/j.csite.2022.102378
14. Palanisamy, K. and Kumar, P.C.M. (2017) Heat transfer enhancement and pressure drop analysis of a cone helical coiled tube heat exchanger using MWCNT/water nanofluid. Journal of Applied Fluid Mechanics, 10, 7–13. https://doi.org/10.36884/jafm.10.SI.28265
15. Umar Ibrahim, I., Sharifpur, M. and Meyer, J.P. (2024) Mixed Convection Heat Transfer Characteristics of Al2O3 – MWCNT Hybrid Nanofluid under Thermally Developing Flow; Effects of Particles Percentage Weight Composition. Applied Thermal Engineering, Elsevier Ltd. 249, 123372. https://doi.org/10.1016/j.applthermaleng.2024.123372
16. Painuly, A., Joshi, G., Negi, P., Zainith, P. and Mishra, N.K. (2025) Experimental analysis of W/EG based Al2O3-MWCNT non-Newtonian hybrid nanofluid by employing helical tape inserts inside a corrugated tube. International Journal of Thermal Sciences, Elsevier Masson SAS. 208, 109399. https://doi.org/10.1016/j.ijthermalsci.2024.109399
17. Khalili Najafabadi, M., Hriczó, K. and Bognár, G. (2024) Enhancing the heat transfer in CuO-MWCNT oil hybrid nanofluid flow in a pipe. Results in Physics, 64. https://doi.org/10.1016/j.rinp.2024.107934
18. Scott, T.O., Ewim, D.R.E. and Eloka-Eboka, A.C. (2023) Experimental study on the influence of volume concentration on natural convection heat transfer with Al2O3-MWCNT/water hybrid nanofluids. Materials Today: Proceedings, Elsevier Ltd. c, 0–6. https://doi.org/10.1016/j.matpr.2023.07.290
19. Pak, B.C. and Cho, Y.I. (1998) Hydrodynamic and heat transfer study of dispersed fluids with submicron metallic oxide particles. Experimental Heat Transfer, 11, 151–70. https://doi.org/10.1080/08916159808946559
20. H.C., B. (1952) The viscosity of concentrated suspensions and solutions. J Chem Phys 20 571,.
21. Xu, J.Z., Gao, B.Z. and Kang, F.Y. (2016) A reconstruction of Maxwell model for effective thermal conductivity of composite materials. Applied Thermal Engineering, 102, 972–9. https://doi.org/10.1016/j.applthermaleng.2016.03.155
22. Oflaz, F. (2025) Evaluation of the thermo ‑ hydraulic behavior of water ‑ based graphene and ­ Al2O3 hybrid nanofluids in a circular tube through CFD simulations. Journal of Thermal Analysis and Calorimetry, Springer International Publishing. https://doi.org/10.1007/s10973-025-13993-4
23. Keklikcioglu, O. (2023) Optimization of thermal and hydraulic characteristics of a heat exchanger tube using ternary hybrid nanofluids with various configurations. Journal of Thermal Analysis and Calorimetry, Springer International Publishing. 148, 7855–67. https://doi.org/10.1007/s10973-023-12263-5
24. Suseel Jai Krishnan, S., Momin, M., Nwaokocha, C., Sharifpur, M. and Meyer, J.P. (2022) An empirical study on the persuasive particle size effects over the multi-physical properties of monophase MWCNT-Al2O3 hybridized nanofluids. Journal of Molecular Liquids, Elsevier B.V. 361, 119668. https://doi.org/10.1016/j.molliq.2022.119668
25. Ao, S.I., Castillo, O., Douglas, C., Dagan Feng, D. and Korsunsky, A.M. (2017) Proceedings of the international multiconference of engineers and computer scientists 2017. Lecture Notes in Engineering and Computer Science, 2227.
26. F.W. Dittus, L.M.K.B. (1930) Heat transfer in automobile radiators of the tubular type. The University of California Publications on Engineering, 2, 443–61.
27. Gnielinski, V. (1976) New equations for heat and mass transfer in turbulent pipe and channel flow. International Chemical Engineering, 27, 359–368.
28. H. Blasius. (1913) The Law of Similarity for Frictions in Liquids, ”Notices of research in the field of engineering. Not Res F Eng, 131, 1–41.
29. McAdams, W.H. (1942) Heat Transmission. (Second Ed), McGraw-Hill, New York,.
30. B.S. Petukhov. (1970) Heat Transfer and Friction in Turbulent Pipe Flow with Variable Physical Properties. Advances in Heat Transfer, 6, 503–64.
31. Togun, H., Homod, R.Z., Yaseen, Z.M., Abed, A.M., Dhabab, J.M., Ibrahem, R.K. et al. (2022) Efficient Heat Transfer Augmentation in Channels with Semicircle Ribs and Hybrid Al2O3-Cu/Water Nanofluids. Nanomaterials, 12. https://doi.org/10.3390/nano12152720
32. Hu, Q., Qu, X., Peng, W. and Wang, J. (2022) Experimental and numerical investigation of turbulent heat transfer enhancement of an intermediate heat exchanger using corrugated tubes. International Journal of Heat and Mass Transfer, Elsevier Ltd. 185, 122385. https://doi.org/10.1016/j.ijheatmasstransfer.2021.122385
33. Qi, C., Wan, Y.L., Li, C.Y., Han, D.T. and Rao, Z.H. (2017) Experimental and numerical research on the flow and heat transfer characteristics of TiO2-water nanofluids in a corrugated tube. International Journal of Heat and Mass Transfer, Elsevier Ltd. 115, 1072–84. https://doi.org/10.1016/j.ijheatmasstransfer.2017.08.098