Converting Klaus Union or other Hydraulic Pumps into Supercritical CO2 Expanders for Energy Recovery

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Alternative Supercritical CO2 Expanders

A novel retrofit approach using Klaus Union pumps for converting waste heat into clean energy by integrating supercritical CO2 expanders and generator systems from Infinity Turbine.

Converting Klaus Union or other Hydraulic Pumps into Supercritical CO2 Expanders for Power Generation

As energy efficiency and heat recovery continue to gain importance across industries, engineers are turning to innovative retrofitting solutions. One promising strategy involves converting Klaus Union pumps into supercritical CO2 (sCO2) expanders to recover energy from low-grade heat sources such as data centers, industrial processes, and concentrated solar systems.

This article outlines the concept, key technical considerations, and power generation potential of using Klaus Union magnetic drive pumps modified with a high-efficiency expander head and generator system.

The Concept

Klaus Union pumps are known for their sealless magnetic drive design, making them ideal candidates for transformation into high-pressure expander systems. By replacing the impeller assembly with a radial or axial turbine expander head, the pump becomes capable of converting the energy in high-pressure supercritical CO2 into mechanical torque.

This torque can then be coupled—via the existing magnetic drive—to either:

A converted induction motor acting as a generator, or

A dedicated 3-phase generator as a direct replacement for the motor.

The design enables closed-loop thermodynamic cycles, using waste heat to elevate CO2 to supercritical states, and then harvesting energy during expansion.

Supercritical CO2 Cycle Basics

Supercritical CO2 behaves like both a gas and a liquid above its critical point:

Critical temperature: 31.1 °C (88.0 °F)

Critical pressure: 7.38 MPa (1,071 psi)

In energy recovery applications, CO2 is pressurized and heated using waste heat sources:

Data Centers: Waste oil or water at 45 to 60 °C

Industrial Processes: Heat from condensate or exhaust streams at 100 to 300 °C

Concentrated Solar: Direct heating above 200 °C

When the CO2 is expanded through the turbine head (formerly the pump head), the pressure drop drives rotation. This rotation is harvested by the generator.

Input Conditions and Energy Output

Input Conditions (Typical Ranges):

Temperature: 90 °C to 300 °C (194 °F to 572 °F)

Pressure: 1,200 psi to 3,500 psi

Flow rate: 10 to 100 kg/min depending on expander size

Power Output Estimate:

Using a heat input of 41.67 MW thermal per hour and an sCO2 turbine efficiency between 5% and 10%, the system could yield:

2 to 4 MW of electrical power

For smaller modular units (e.g., 250 kW), multiple units can be ganged into a Cluster Mesh Power Generation system

Advantages of This Retrofit Approach

Cost-Effective: Reuses robust industrial-grade Klaus Union pump bodies

Compact and Modular: Ideal for tight industrial or data center environments

No Seals Required: Magnetic drive preserves hermetic sealing

High Energy Density: Supercritical CO2 has low compression losses and high expansion energy

Sustainability: Captures otherwise lost low-grade heat for power production

Technical Considerations

Expander Design:

Radial inflow turbines are compact and efficient for sCO2

Materials must withstand high pressures and temperatures

Magnetic Coupling Integrity:

Assess torque transmission capability at high RPMs

Upgrade magnets or bearings if necessary

Generator Integration:

Induction generator (self-excited or externally excited)

3-phase permanent magnet generator (for higher efficiency and compact size)

System Integration:

Must include heat exchangers, recuperators, and pressure regulators

CO2 loop must be leak-tight and corrosion-resistant

Applications

Data Center Heat Recovery: Turns GPU and server heat into electricity and cooling

Industrial Waste Heat Recovery: Recovers power from flue gas, steam condensate, or heated liquids

Solar Thermal Systems: Directly couples to solar concentrators for off-grid power

Conclusion

Repurposing Klaus Union pumps as supercritical CO2 expanders is a practical and innovative way to capitalize on existing infrastructure. The modularity and reliability of these systems offer a scalable pathway to low-grade heat-to-power conversion, driving energy efficiency in the next generation of industrial and data center applications.

Updated 2024

Cost-benefit analysis for retrofitting a hydraulic pump into a supercritical CO2 expander

Here is a cost-benefit analysis for retrofitting a Klaus Union pump into a supercritical CO₂ expander system for power generation using waste heat. This includes upfront capital, operational parameters, and estimated return on investment (ROI) over 10 years.

1. Capital Costs

Component Estimated Cost (USD)

Used Klaus Union Magnetic Drive Pump $8,000 – $15,000

Custom Expander Head (Radial/Axial) $20,000 – $40,000

Magnetic Coupling Modifications $2,000 – $5,000

3-Phase Generator or Induction Gen $8,000 – $20,000

Heat Exchanger & Recuperator Setup $15,000 – $30,000

High-Pressure CO₂ Loop (Piping, Vessels) $25,000 – $50,000

Control Electronics + Safety Systems $5,000 – $10,000

Installation & Engineering $15,000 – $25,000

Total Estimated Capital Cost $98,000 – $195,000

2. Operating Parameters

CO₂ Input Temp: 150–300°C (302–572°F)

CO₂ Input Pressure: 1,500–3,500 psi

Thermal Input Requirement: ~41.67 MWth per hour for full output

Net Power Output per Unit: 200–500 kW (up to 4 MW for larger setups)

Annual Uptime: 7,500 hours/year (assumes continuous industrial use with maintenance downtime)

3. Operating Costs (Annual)

Item Estimated Annual Cost (USD)

Maintenance (gaskets, sensors) $2,000 – $4,000

Utilities (cooling fluid, aux power) $1,500 – $3,000

Labor & Inspection $2,500 – $5,000

Insurance & Regulatory $1,000 – $2,500

Total OPEX $7,000 – $14,500

4. Revenue and Savings

Assumptions:

Electricity sale or offset value = $0.10/kWh

Power generated = 250 kW average

Annual runtime = 7,500 hrs

Annual Revenue or Savings:

250 kW × 7,500 hrs = 1,875,000 kWh/year

Revenue = $187,500/year

5. Return on Investment (ROI)

Metric Estimate

Payback Period (simple) 0.5 to 1.1 years

10-Year Revenue $1.875 million

10-Year Net Profit (after OPEX) $1.73M – $1.80M

ROI over 10 years 900% – 1,200%

6. Additional Benefits

Emission Reduction: Avoids CO₂ emissions from peaker plants or grid electricity

Waste Heat Utilization: Converts waste streams into revenue

Scalability: Multiple units can be ganged into a Cluster Mesh

Low Maintenance: Magnetic coupling reduces seal failures

Conclusion

Retrofitting Klaus Union pumps as sCO₂ expanders is a highly cost-effective energy recovery strategy, especially when integrated with industrial or data center operations. With fast ROI and significant long-term revenue, it provides a path toward decarbonization, waste heat reuse, and grid resilience.

Industries and Applications for sCO₂ Expander-Based Power Generation

Retrofitting hydraulic pumps into supercritical CO₂ (sCO₂) expanders opens up opportunities across a wide range of industries where waste heat is abundant or process heat is already available. Below is a breakdown of industries and applications ideally suited for this type of power generation system:

Industries and Applications for sCO₂ Expander-Based Power Generation

1. Data Centers

Application: Capturing heat from GPUs, CPUs, and power supplies (typically 45–60°C oil or water).

Benefit: Simultaneous cooling and electricity generation; reduces HVAC and energy costs.

Example: Infinity Turbine Cluster Mesh concept for modular sCO₂ generation per server rack row.

2. Industrial Manufacturing

Sub-sectors:

Steel and aluminum mills

Cement kilns

Glass and ceramics production

Chemical processing

Paper and pulp industry

Application: Recovering heat from exhaust flue gases, hot liquids, or process steam.

Benefit: Turns waste into base-load power without affecting primary processes.

3. Oil and Gas

Application: Using flare gas heat, separation unit heat, or compressor station waste heat.

Benefit: Local power generation in remote or off-grid locations; enhances site efficiency.

Potential: Can be configured in hazardous or offshore environments using sealless design.

4. Geothermal Energy

Application: Using medium-temperature geothermal brines (90–150°C) for direct CO₂ heating.

Benefit: Higher cycle efficiency compared to Organic Rankine Cycle (ORC) at similar temperatures.

5. Concentrated Solar Power (CSP)

Application: Directly using high-temperature solar thermal fluid to heat sCO₂.

Benefit: Higher thermodynamic efficiency than traditional steam Rankine or ORC.

Note: Works well with modular, distributed solar thermal setups.

6. Waste-to-Energy Plants

Application: Utilizing heat from incineration or anaerobic digestion processes.

Benefit: Converts municipal or industrial waste into both thermal and electric energy.

Supplementary Use: For landfill gas or biogas operations.

7. Marine and Naval Systems

Application: Harvesting engine waste heat onboard ships or submarines.

Benefit: Reduces fuel consumption by generating onboard electricity from existing heat.

8. Hydrogen and Electrolysis Plants

Application: Capturing heat from hydrogen production via electrolysis or SMR.

Benefit: Improves plant-wide efficiency by turning byproduct heat into electricity.

9. Mining Operations

Application: Utilizing geothermal heat or exhaust heat from ore processing machinery.

Benefit: Enables off-grid power in remote, harsh environments.

10. District Heating and Energy Recovery Systems

Application: Integrated into combined heat and power (CHP) setups where thermal loads vary.

Benefit: Shifts excess heat into power during low heating demand periods.

Key Advantages for Industry

Operates efficiently at medium temperatures (90–300°C)

Compact, modular design suited to constrained or retrofitted spaces

High-pressure CO₂ cycle means greater power density

Works with low-grade and variable heat sources

Low maintenance via magnetic coupling and sealless design

Updated January 2025