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.