The global energy landscape is evolving rapidly, driven by the need for more efficient, flexible and sustainable power generation. As energy demands increase, dispatchable generation units and innovative energy storage systems are critical to ensuring both supply security and system stability. In this context, supercritical carbon dioxide (sCO₂) power cycles have emerged as a groundbreaking alternative to traditional water-steam cycles, offering significant advantages in efficiency and system compactness. Kelvion, the global leader in heat exchange technology, is proud to partner in the ESCO research project, which aims to optimise sCO₂ cycle technology for industrial applications. As part of this initiative, Kelvion will develop cutting-edge 3D-printed heat exchanger prototypes using advanced materials specifically designed for sCO₂ systems, reaffirming its commitment to driving sustainable energy innovations.
Pioneering Heat Exchanger Design with 3D technology
Unlike conventional steam turbines, turbomachines using supercritical CO₂ are more compact and require highly efficient heat recovery through innovative heat exchangers. The unique properties of sCO₂ necessitate precise aerodynamic optimisation, advanced sealing and bearing technologies, as well as materials capable of withstanding extreme pressures and temperatures.
Through 3D topological optimisation and the use of next-generation materials, Kelvion is developing high-performance heat exchangers tailored to these demanding conditions. The adoption of 3D printing not only enables greater design flexibility but also promises significantly reduced production times compared with traditional manufacturing methods. Once proven, these advancements will pave the way for broad commercialisation and industry adoption.
Transforming Energy-Intensive Industries
While water-steam cycles are well-established and widely used in power generation, the energy transition is driving increased interest in alternative technologies such as sCO₂. Historically, demand for sCO₂ systems has been limited, especially in Europe. However, the growing need for higher efficiency and reduced environmental impact is shifting this dynamic.
Supercritical CO₂ power cycles offer several advantages:
- Higher efficiency compared with conventional systems.
- Smaller, more compact components, which simplify system design and reduce costs.
- Minimal water usage
These benefits position sCO₂ technology as a transformative solution for sectors such as waste heat recovery, geothermal energy, solar thermal applications, and thermal energy storage systems.
“Kelvion’s involvement in the ESCO project reflects our commitment to advancing energy technology and sustainability,” says Stefan Ziegler (VP Research and Innovation). ” By collaborating with leading industry partners, we aim to redefine heat exchanger design, establish new industry standards, and drive transformative change in global energy systems. Together, we are contributing to a more efficient, sustainable energy future.”
About Kelvion
Kelvion is the leading global developer and manufacturer of heat exchange solutions. Renowned for its commitment to innovation and sustainability, the company delivers cutting-edge thermal management solutions that empower customers to ensure reliable and efficient operations. Kelvion’s extensive portfolio serves a wide range of applications such as data centres, crypto mining, hydrogen production, heat pumps, marine, HVAC, refrigeration and the food and beverage industry. The company’s global sales, service and production network ensures that Kelvion is always available to support customers wherever they are. Whether supporting site installation, providing on-site technical service or replacement parts – Kelvion’s comprehensive range of service offerings is designed to optimise performance and extend the product lifecycle to ensure sustainability and reliability.
About ESCO
With the transformation of energy systems taking place worldwide, the further development and expansion of dispatchable generation units and energy storage systems to maintain security of supply and system stability as well as heat supply, must be driven forward. Due to the special properties of carbon dioxide above the critical point (31°C, 73.8 bar), there are advantages to using it in thermodynamic cycle processes. These cyclic processes achieve higher efficiencies and a significant reduction in the size and complexity of the individual components. This enables the more efficient use of industrial (waste heat), geothermal and solar heat sources as well as thermal energy storage systems. Heat sources that could not previously be used economically therefore show potential for stable energy supply. However, there are some challenges and a need for research before commercialisation can be driven forwards. The main challenges for sCO2 turbomachines include heat recovery, aerodynamic optimisation, new sealing and bearing technologies, material suitability for high pressure/temperature, and limited operational experience with control systems. These will be addressed to improve technical maturity.
The overarching objective of the project is to tackle these challenges and create the fundamental technical design of systems and components of sCO2 cycles for waste heat recovery and thermal energy storage. The ESCO project builds directly on the results generated in the previous CARBOSOLA project
(https://www.hzdr.de/db/Cms?pOid=63555&pNid=0&pLang=de) and the knowledge gained can be used in the construction of a technology demonstrator. Individual components, such as the heat exchangers and the flow measurement technology, will be further developed up to the test setup in the laboratory and suitable materials will be validated under CO2 atmosphere.
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