High Effectiveness, Compact, High Pressure and Low Cost Recuperator for Super-Critical CO2 Power Cycles, Paper Presented at The Fifth International Symposium – Super-Critical CO2 Power Cycles, San Antonio, Texas, March 28-31, 2016, by Dr. John Kelly, President, Altex Technologies Corporation
Closed Brayton super-critical CO2 power cycles are well suited to waste heat bottoming cycles, due to their increased efficiency and compactness, relative to Rankine steam bottoming cycles. Since waste heat applications would be retrofits, the power system compactness is important. To achieve high efficiency, these power cycles require high pressure recuperative type heat exchangers, of substantial heat duty. Current Printed Circuit Heat Exchangers (PCHE), originally developed for high pressure gas and oil applications, can be used as recuperators, but costs are higher than desired. Altex is developing a purpose-built high pressure and effectiveness recuperator to provide the reliability, compactness, performance and pressure capability of current recuperators, but at a reduced cost. The High Effectiveness Low Cost (HELC) recuperative heat exchanger design yields volume and weight metrics of .0024 m3/UA and 10.2 kg/UA, which are 4% and 77.3% below recuperator target metrics, respectively. A 50 kW test article was designed and fabricated. Performance tests on water and oil showed that the HELC design model could predict heat transfer, to within 10% of the measured value. This model was then used to project HELC performance, when operating on supercritical CO2. Besides performance tests, the test article was hydrostatically tested, for integrity at up to 4,000 psi pressure. At these conditions, some distortion of channels was encountered. To mitigate distortion, the inserts were redesigned and these results were used to project the cost of 500 kW and 5,083 kW HELC units. The cost metric for the 5,083 kW unit was determined to be $1,349/UA, which is 10% lower than the recuperator desired cost metric desired target of $1,500/UA. In addition, the 5,083 kW unit HELC cost of $61.09/kW is 33.6% lower than the $92/kW estimated cost for a PCHE. Hydrostatic pressure tests, at up to 4,000psi, showed that the unit did not leak. However, channels were distorted at this pressure differential. Design updates to minimize stress concentrations and distortion were prepared and analyzed, to show that distortion could be controlled, but to date tests have not been run to prove the design. Project results show the potential of the HELC approach, but more work is required to confirm this potential, at the larger scales of interest.