Microstructure and Corrosion Changes Due to Spray Cooling: How Synthesized Wastewater Effects the Electroless Composite Coating

Heat exchangers are very crucial and easily available devices in chemical industries. Shell and tube heat exchanger are the most common amongst them. Mild steel, on other hand, is used as the basic structural material for manufacturing heat exchangers. Water is also considered as a very important environmental resource of current date. The present study focuses on synthesis of electroless Ni–P–Cu-coated mild steel utilizing the wastewater for heat transfer analysis. An inbuild laboratory-scale technique of spray cooling has been utilized for analysing the heat transfer study. The surface morphology and phase structure analysis has been carried forward using SEM and XRD results. The microhardness study of the sample has been analysed and reported. The material corrosion behaviour has also been reported stating the temperature 400 °C ideal for heat treatment maintaining corrosion resistance of the composite coating at the given scenario. Finally, the heat transfer coefficient study reveals a result of 3.69 KW/m²/ K for the optimized sample of Ni–P–Cu–1. The process aims to reutilize and retreat the wastewater in the most productive way following the concept of sustainability respectively.