S-CO2发电系统构型优化与工业余热场景应用分析

Configurations Optimization and Application Analysis on S-CO2 Power System for Multi-scenario Industrial Waste Heat Recovery

  • 摘要: 2025年12月20日,全球首台商用超临界二氧化碳(S-CO2)发电机组“超碳一号”在贵州六盘水成功投运,是S-CO2发电技术实现工业化应用的里程碑。该技术具备向其他工业场景推广的潜力,但需要解决适配不同热源的循环优化设计问题。本研究针对烧结机余热发电、轻型燃气轮机联合循环余热发电及干熄焦余热发电3种场景,对S-CO2循环进行了热力性能评估与构型优化。结果表明,预热循环通过分流预热结构减少了回热器内部的不可逆损失,相较于简单回热循环显著提高了循环净功;双透平级联循环可拆分为两个预热循环,通过分流膨胀机制,能维持稳定的透平进口温度;热力循环理论性能曲线为基于热源品位的构型选择提供了定量依据。本研究可为其他场景S-CO2发电示范项目提供理论支撑。随着S-CO2发电技术从单点示范迈向商业化应用,有望推动传统发电技术的转型升级。

     

    Abstract: This study focuses on the configuration optimization of supercritical carbon dioxide (S-CO2) power cycles for multi-scenario industrial waste heat recovery, aiming to enhance power generation performance and improve adaptability across a wide range of heat source temperature conditions. With the gradual commercialization of S-CO2 power systems, their application is expanding from nuclear energy systems with relatively stable heat sources to industrial waste heat recovery scenarios characterized by strong temperature variability. Conventional configurations, such as the simple recuperated cycle (SRC) and recompression cycle (RC), often show limited adaptability under different thermal conditions, making it difficult to achieve efficient waste heat utilization across a broad operating range. To address this issue, a unified thermodynamic evaluation framework was developed to systematically compare and optimize multiple S-CO2 cycle configurations, with particular emphasis on improving both energy conversion efficiency and waste heat recovery capability. The methodology was based on thermodynamic and exergy modeling of key components, including compressors, turbines, recuperators, heaters, and coolers. Three non-split cycle configurations and eight flow-splitting configurations were investigated. The flue gas outlet temperature of the heater (Thout) was treated as the primary independent variable, and a parametric optimization strategy was employed. For each fixed Thout, cycle parameters were optimized to maximize net power output, and the corresponding optimal cycle efficiency was obtained. By continuously varying Thout, performance maps of different cycle configurations were established, revealing the coupling relationship between heat source temperature levels and optimal cycle selection. The results show that the preheating cycle (PHC) significantly improves temperature matching in the recuperator via flow-splitting, thereby reducing exergy destruction and increasing net power output. In contrast, RC exhibits higher efficiency under high-temperature conditions but limited capability for deep recovery of low-grade waste heat. The dual-turbine cascade cycle (DTC) maintains relatively stable turbine inlet temperatures via split-expansion, demonstrating improved performance at low Thout conditions, although at the cost of increased system complexity. Furthermore, for coke dry quenching waste heat recovery, a newly proposed hybrid configuration combining split-expansion, recompression, and preheating (DTC_RC_PHC) shows enhanced thermodynamic performance at low Thout conditions (≤200 ℃). However, the system complexity significantly increases. Overall, no single S-CO2 cycle configuration is universally optimal across all operating conditions, as performance is strongly governed by heat source characteristics. The performance maps developed in this study provide a systematic basis for cycle selection under different industrial waste heat scenarios and offer useful guidance for the engineering application of S-CO2 power generation systems in multi-scenario waste heat recovery.

     

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