Advances in thermal–hydraulic performance and dynamic behavior of supercritical CO2 in printed circuit heat exchangers: mechanisms, innovations, and future perspectives

• Published in: The International journal of heat and fluid flow Vol. 116; p. 109953
• Main Authors: Chen, Junlin, Du, Wenhai, Cheng, Keyong, Li, Xunfeng, Huai, Xiulan, Guo, Jiangfeng, Lv, Pengfei, Dong, Hongsheng
• Format: Journal Article
• Language: English
• Published: Elsevier Inc 01.12.2025
• Subjects: Dynamic thermal–hydraulic characteristic; Flow and heat transfer characteristic; Performance evaluation; Printed circuit heat exchanger; Supercritical CO2; Performance evaluation; Flow and heat transfer characteristic; Printed circuit heat exchanger; Dynamic thermal–hydraulic characteristic; Supercritical CO2
• ISSN: 0142-727X
• DOI: 10.1016/j.ijheatfluidflow.2025.109953

[Display omitted] •Developments of buoyancy and acceleration effects and pseudo-boiling theory are summarized.•Many novel structures for enhanced heat transfer are summarized.•Dynamic heat transport characteristics and thermal inertia in PCHEs needs more research.•New theories offer optimization strategies for PCHE design and performance evaluation.•Future research should unify heat transfer mechanisms and consider PCHE’s flexibility. The supercritical carbon dioxide Brayton cycle (SCO2-BC) represents a transformative advancement in power generation, offering exceptional efficiency and compactness, particularly for renewable energy integration. Among the heat exchanger technologies suited for SCO2-BC, printed circuit heat exchangers (PCHEs) stand out due to their superior thermal performance and adaptability under extreme conditions. This review critically examines recent advancements in the thermal–hydraulic characteristics and dynamic performance of PCHEs in SCO2 systems. Key topics include flow and heat transfer behaviors under steady and dynamic conditions, innovative heat transfer structures, and performance evaluation using thermodynamic laws. Key breakthroughs include novel channel designs such as airfoil fins, pseudo-boiling theory, and artificial intelligence-driven performance predictions, which represent groundbreaking enhancements in efficiency. Persistent challenges—such as unifying heat transfer mechanisms, characterizing thermal inertia, and optimizing transient off-design performance—are also highlighted. Future research directions emphasize channel design optimization, flexibility/safety enhancements, and comprehensive evaluation criteria. This work consolidates current understanding and guides future PCHE development for advanced energy applications.