Design, Modeling, and Testing of a Novel Elastohydrodynamic Seal for Supercritical CO₂ Power Cycles

Effective sealing is a critical challenge in achieving the full potential of supercritical carbon dioxide (sCO₂) power generation. Leakages from sCO₂ cycles can reduce efficiency by up to 0.65%, underscoring the need for advanced sealing solutions. This study explores an elastohydrodynamic (EHD) seal as a promising option, designed to minimize leakage and wear under sCO₂ conditions. A fluid–solid coupling model, based on finite element analysis and computational fluid dynamics, was developed and experimentally validated. Proof-of-concept tests were conducted on a 2-in. static shaft seal with pressures up to 1.2 MPa, using polytetrafluoroethylene (PTFE) as the seal material. Both simulations and experiments revealed a quadratic leakage trend: leakage initially increased with pressure, peaked at about 6 g/s, and then declined to approximately 1.5 g/s at maximum pressure. The model proved efficient, converging in just 2 s, while providing insights into leakage rates, seal deformation, clearance pressure, and stress. In addition, a modified model was provided, which converged in less than 20 s with added accuracy. A parametric analysis further demonstrated the impact of key design factors on leakage, with results aligning with physical expectations. The proposed models could serve as a valuable design tool for EHD seals.