In this analysis, the interfacial layer and shape effects has been inspected numerically for the Darcy Forchheimer electromagnetic flow of single-walled carbon nanotubes (SWCNT) and multi-walled carbon nanotubes (MWCNTs) with base fluid (water) nanofluids. The influence of nonlinear thermal radiation and homogenous and heterogeneous chemical reactions are also taken into account. A revised Hamilton Crosser model is implemented for measuring interfacial layer and shape effects of carbon nanotubes-water nanofluid. The flow problem for examining the heat transfer features has been modeled in term of nonlinear equations by incorporating the Hamilton–Crosser model. The main objective for performing the current work is to analyze how the shapes of nanoparticles effect towards the flow of considered fluid with various thermal features. The entropy generation analysis is performed as novelty. The governing dimensionless equations are numerically solved by fourth order Runge–Kutta method computational shooting technique. The relevant parameter variations on axial, radial, tangential velocity, temperature, concentration, skin friction, Nusselt number, entropy generation rate and Bejan number are highlighted. The enhanced shape factor of nanoparticles contributes to accelerated flow along axial and radial directions while it yields decelerated flow along tangential direction of lower and upper disks. The augmented interfacial layer parameter enhances heat transportation from the surfaces of lower and upper disks.