THERMAL PERFORMANCE ENHANCEMENT OF HYBRID NANOFLUID-BASED HEAT EXCHANGERS FOR INDUSTRIAL ENERGY EFFICIENCY APPLICATIONS IN PAKISTAN

Abstract

Improving thermal energy utilization has become a strategic priority for enhancing industrial productivity, reducing operational costs, and achieving sustainable manufacturing, particularly in energy-intensive industries in Pakistan. Conventional heat transfer fluids exhibit limited thermal conductivity, which restricts the performance of industrial heat exchangers and contributes to higher energy consumption. This study investigated the thermal performance enhancement of hybrid nanofluid-based heat exchangers for industrial energy efficiency applications in Pakistan using an integrated experimental and Computational Fluid Dynamics (CFD)-based approach. Five hybrid nanofluid formulations, namely Al₂O₃–CuO, TiO₂–SiO₂, Graphene–Al₂O₃, CuO–MWCNT, and Fe₃O₄–Graphene, were evaluated under varying nanoparticle concentrations and Reynolds numbers. Thermal performance was assessed through heat transfer coefficient, Nusselt number, pressure drop, friction factor, pumping power, thermal efficiency, exergy efficiency, and thermo-economic performance. CFD simulations using ANSYS Fluent were employed to validate the experimental observations and optimize operating conditions. The study further incorporated exergy and thermo-economic analyses to evaluate the technical and economic feasibility of hybrid nanofluid implementation in industrial heat exchangers. The findings are expected to provide a comprehensive understanding of the thermo-hydraulic behavior of hybrid nanofluids and identify optimized operating conditions that maximize heat transfer while minimizing hydraulic losses and energy consumption. The study contributes to the advancement of thermal engineering by integrating experimental validation, CFD modeling, and thermodynamic optimization within the context of Pakistan's industrial sector. The findings are anticipated to support the adoption of advanced heat transfer technologies, enhance industrial energy efficiency, reduce greenhouse gas emissions, and promote sustainable industrial development