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Design
Flow diagram supercritical CO2 Power cycle .
Printed circuit heat exchanger in sCO2 cycle test installation Helmholtz Dresden .
etching and diffusion bonding technologies . Metal plates , etched with intricate flow channels , are stacked and bonded to form a solid block capable of withstanding high pressures and temperatures . This construction method allows for sophisticated channel designs that enhance heat transfer within a minimal footprint , making PCHEs an ideal choice for sCO2 power cycle recuperators . [ 1 ]
New channel patterns for enhanced efficiency Traditionally , PCHEs feature either straight or zig-zag flow channels , depending on the specific characteristics of the working fluid . Straight channels are typically used for phasechange processes like evaporation or condensation , while zigzag channels are preferred for single-phase fluids . However , research has suggested that alternative shapes , such as airfoil or S-shaped channels , could offer superior performance . But none comprehensively addressed all manufacturing and mechanical constraints . Indeed , the dimensions and arrangement of the shapes must align with the requirements of the chemical etching process and ensure sufficient contact surface to prevent any excessive deformation during the diffusion bonding of plates . Obviously , the design pressure (> 200 bar ) and temperature (> 600 ° C ) have also a significant impact on spacing and height of these shapes . Kelvion took this insight further by developing an optimised channel pattern that balances manufacturing constraints with performance goals . Using advanced mechanical finite element analysis ( FEA ) and computational fluid dynamics ( CFD ), Kelvion ’ s engineers developed a new shape that reduces pressure losses while maintaining high heat
Product rendering . transfer efficiency . The optimised pattern has been validated through testing at the Technische Universität Wien , where two prototypes — one with conventional zig-zag channels and one with Kelvion ’ s new design — were compared . “ The results showed that the new pattern achieved up to 20 % lower pressure drop while delivering equivalent heat transfer performance ,” says Xavier Guerif , PCHE Product Line Manager at Kelvion . Alternatively , the new design could reduce the number of plates required by 10 % without compromising efficiency .
Broader applications beyond sCO2 cycles Kelvion ’ s advances in channel pattern design have the potential to benefit a wide range of applications beyond sCO2 power cycles . The improved efficiency and reduced pressure drop of the new PCHE design can also be applied to :
• Natural gas compression
• Hydrogen compression
• CO2 compression
• Nuclear power plants
• Geothermal energy systems
These advancements demonstrate Kelvion ’ s commitment to delivering cutting-edge solutions that meet the evolving needs of the energy industry .
Conclusion Printed Circuit Heat Exchangers ( PCHEs ) have emerged as the preferred technology for the recuperator section of supercritical CO2 power cycles , offering significant efficiency advantages over conventional steam cycles . With this newly introduced advanced channel pattern , these benefits are taken even further . By reducing pressure drop while maintaining superior heat transfer , Kelvion ’ s innovations promise to make sCO2 power cycles — and a wide range of other applications — more efficient , compact , and cost-effective .
References 1 . Edgar-Lane , Chris . Understanding printed circuit heat exchangers & the role of chemical etching . Precision Micro . [ Online ] [ Cited : May 1 , 2024 .] https :// www . precisionmicro . com / understanding-printed-circuitheat-exchangers-the-role-of-chemical-etching /.
2 . Patel , Sonal . What are superctitical CO2 power cycles ? Power Magazine . [ Online ] April 1 , 2019 . https :// www . powermag . com / what-are-supercritical-co2-power-cycles /. www . heat-exchanger-world . com Heat Exchanger World October 2024
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