Dispatchable generation units and innovative energy storage systems are critical to the rapidly evolving global energy landscape.
In this new environment 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.
To optimise CO₂ cycle technology for industrial applications, Kelvion has joined the ESCO research project.
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.
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.
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 VP of research & innovation, Stefan Ziegler, said Kelvion’s involvement in the ESCO project reflects the company’s commitment to advancing energy technology and sustainability.
“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,” Ziegler said.