Heat transfer analysis of nanofluid flow with entropy generation in a corrugated heat exchanger channel partially filled with porous medium

Heat exchanger research is mainly exploited to develop and optimize new engineering systems with high thermal efficiency. Passive methods based on nanofluids, fins, wavy walls, and the porous medium are the most attractive ways to achieve this goal. This investigation focuses on heat transfer and entropy production in a nanofluid laminar flow inside a plate corrugated channel (PCC). The channel geometry comprises three sections, partially filled with a porous layer located at the intermediate corrugate channel section. The physical modeling is based on the laminar, two-dimensional Darcy–Brinkman–Forchheimer formulation for nanofluid flow and the local thermal equilibrium model for the heat equation, including the viscous dissipation term. Numerical solutions were obtained using ANSYS Fluent software based on the finite volume technique and the appropriate meshed geometries. The numerical results are validated with theoretical, numerical, and experimental studies. The simulations are performed for CuO–water nanofluid and AISI 304 porous medium. The coupled effects of porous layer thickness (δ), Reynolds number (Re), and nanoparticle fraction (φ) on velocity, streamlines, isotherm contours, Nusselt number (Nu), and entropy generation (S) are analyzed and illustrated. The simulation results demonstrate that heat transfer enhancement in clear PCC can be achieved using a porous layer insert. For the porous thickness range of [0.1–0.6], the corresponding range of average Nusselt number increase is [35.7%–176.9%], and the average entropy generation is [105.4%–771.9%]. The effect of the Reynolds number is more important in a porous duct than in a clear one. For δ = 0.4 and φ = 5%, the increase of Re in the range of [200–500] induces an increase in average Nusselt number in the range of [80.9%–108.4%] and average entropy in [222.9%–309.1%] comparatively to clear PCC. The effect of φ is practically the same for porous and clear channels. For φ = 5%, the increase on average Nu is about 9%, and entropy generation is 5%. Accordingly, important improvements in heat transfer in PCC can be achieved through the combined effect of flow Reynolds number and porous layer thickness.