Review of Micro–Nanoscale Surface Coatings Application for Sustaining Dropwise Condensation

Condensation occurs in most of the heat transfer processes, ranging from cooling of electronics to heat rejection in power plants. Therefore, any improvement in condensation processes will be reflected in the minimization of global energy consumption, reduction in environmental burdens, and development of sustainable systems. The overall heat transfer coefficient of dropwise condensation (DWC) is higher by several times compared to filmwise condensation (FWC), which is the normal mode in industrial condensers. Thus, it is of utmost importance to obtain sustained DWC for better performance. Stability of DWC depends on surface hydrophobicity, surface free energy, condensate liquid surface tension, contact angle hysteresis, and droplet removal. The required properties for DWC may be achieved by micro–nanoscale surface modification. In this survey, micro–nanoscale coatings such as noble metals, ion implantation, rare earth oxides, lubricant-infused surfaces, polymers, nanostructured surfaces, carbon nanotubes, graphene, and porous coatings have been reviewed and discussed. The surface coating methods, applications, and enhancement potential have been compared with respect to the heat transfer ability, durability, and efficiency. Furthermore, limitations and prevailing challenges for condensation enhancement applications have been consolidated to provide future research guidelines.