This article inspects entropy generation and mixed convection boundary layer flow of carbon nanotubes (CNTs) Casson nanoliquid via semi-infinite vertical cylinder which moves with nonlinear velocity in Darcy-Forchheimer porous medium. Appropriate similarity variables have been employed to convert the original partial differential equations into ordinary differential equations that have been solved using overlapping grid spectral quasilinearisation method (SQLM). Comparison of accuracy, convergence and stability between the two methods is made. Rate of entropy generated, flow fields and engineering quantities are discussed for different embedding parameters. It is revealed that single-wall CNTs are more efficacious to improve heat transport features than multi-wall CNTs. The fluid flow and thermal dispersion processes improve with consideration of curved surface, CNTs, non-Newtonian fluid and injection of the fluid. The curvature surface and suction of the fluid contribute towards growth of skin friction factor and rate of thermal transference. Entropy generated expands by accounting for viscous nature of the fluid, strong nonlinearity, suction, non-Newtonian fluid, convective boundary condition and CNTs. The study finds applications in various processes, which are massively impacted by heat transport enhancement and high porosity. Boundary layer flow and heat transfer analysis through cylinders are relevant to various metallurgical and engineering solicitations.
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