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An approximate breakdown of the component equipment costs for an example sCO2 system is shown in Figure 9. As the technology and commercial market matures, we expect that opportunities for significant cost reduction will be realized in the following areas. Recuperators: At present, the supplier base for PCHE’s is only beginning to expand beyond the pioneering company in this field, and new technologies for lower cost compact heat exchangers specifically designed for sCO2 power cycles are being developed under private and government funding [29–31]. It is reasonable to expect that significant improvements in the cost basis of sCO2 cycles will be achieved as these technology and commercial development plans develop into maturity. Exhaust heat exchangers: The physical size of the sCO2 exhaust heat exchanger (EHX) is similar to that of the HRSG. In both sCO2 and steam-based systems, finned tube heat exchangers are used, and the limiting heat transfer coefficient is the exhaust heat transfer by convection to the fin and tube surfaces, representing 85-95% of the overall thermal resistance. Therefore, the amount of physical surface area needed to extract the same amount of heat from both cycles is similar. The sCO2 exhaust heat exchanger operates at higher pressure than does the HRSG, and thus thicker wall tubing is required, making the tube bundles themselves heavier. However, the higher tube weight of the EHX is offset by the much lower weight of the simple pipe headers compared to the thick-walled steam drums of a conventional HRSG. The smaller wall thickness of the EHX header also simplifies manufacturing, as the ratio of header thickness to tube thickness is much smaller, making the welding process less challenging. In addition, the EHX consists of three coils of similar construction, while a double- pressure HRSG typically can require 6-11 different coils (generally at least a separate economizer, boiler and evaporator for each pressure level), and triple-pressure HRSGs up to 13 coils. In general, we have found that quoted prices for a similar capacity EHX are 30-40% lower than a comparable HRSG, largely due to the simplicity of construction. sCO2 technology offers potential advantages for more compact, and theoretically lower- cost EHX technologies. Combining the high pressure capability of diffusion-bonded heat exchangers with the large surface area and low pressure drop of formed fin geometry, a hybrid heat exchanger [16] could provide a significant advantage over conventional finned tube heat exchangers for EHX service. In a preliminary study of a small-scale (~1.5 MW) system, heat exchanger mass could be reduced by a factor of two, and footprint by a factor of three relative to a finned tube geometry with 50mm tubes. Although significant development is required to implement advanced heat exchanger geometries, the potential for major gains in performance, footprint and cost is clear. Condenser: A steam condenser operates at low vacuum, and therefor large volumetric flow rate of steam. For the 2x2x1 7FA case, the turbine exhaust flow is 3900m3/s, requiring a flow area of at least 80m2, while the sCO2 system has a condenser inlet volumetric flow rate of only 11 m3/s due to the much higher density of CO2 at those conditions. This results in much smaller interconnecting piping, which is particularly important for air cooled systems. However, the higher density is due in part to the much 16PDF Image | SUPERCRITICAL CO2 CYCLES FOR GAS TURBINE COMBINED CYCLE
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