CFD Comparison of Al₂O₃ and ZnO Ceramic Coatings on Non-Insulated Copper Heat Exchangers

Non-insulated heat exchangers in gas-to-gas service lose substantial energy to the surroundings. This study evaluates Al₂O₃ and ZnO ceramic coatings (200 $\mathsf{\mu }$m) as passive thermal retention layers on the inner surface of the outer tube in a copper double-pipe heat exchanger, using 3D CFD simulations verified for internal consistency against Log Mean Heat Transfer Rate analytical solutions. Six cases were modelled: three coating conditions across parallel-flow and counter-flow configurations under laminar conditions ($R{e}_i\approx 525$, $R{e}_o\approx 192$) with air as the working fluid. The coating elevates the outer tube inner wall temperature $T_3$, increasing the convective driving force to the cold fluid while suppressing ambient dissipation. In parallel flow, Al₂O₃ increases the net inter-fluid heat transfer rate by 35.7% and reduces ambient losses by 81.4%; ZnO achieves 30.9% and 70.4%, respectively. In counter-flow, Al₂O₃ yields a 26.6% enhancement and 73.2% loss reduction. The coated parallel-flow configuration outperforms the uncoated counter-flow baseline. Thermal circuit analysis shows that Al₂O₃ superiority arises from its higher conductivity (40 vs. 19 W m⁻¹ K⁻¹), which sustains a higher equilibrium $T_3$ and a heat partition ratio of 11.84 versus 7.17 for ZnO. These results show that a single ceramic coating layer can recover a large fraction of the thermal energy lost through non-insulated walls, offering a low-cost, retrofit-compatible pathway to improve the energy efficiency of gas-to-gas heat exchangers in HVAC, building energy recovery, and industrial process heat applications.