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• Stack-based thermal resistance network model developed for micro channel heat exchangers. • Correlations developed with straight, sinusoidal and zigzag channels for sCO 2 recuperator. • Hybrid model demonstrates that 20 rows are sufficient to attain the correct stack performance. • Several combinations of stack dimensions generated for different channel configurations. • Sinusoidal channel offered least pressure drop and stack volume compared to straight and zigzag channels. In this work, a full-scale Thermal Resistance Network (TRN) coupled with a unit-cell-based CFD model identified as the hybrid model is developed and implemented in designing a Mini Channel Heat Exchanger (MCHE) as a recuperator used in sCO 2 Brayton power block. The TRN framework converts the MCHE domains into a thermal circuit using resistances and advection currents that can be used to model the entire stack with varying thermo-physical properties of working fluids. The results from the TRN model with CFD-based heat transfer and pressure drop correlations developed for different channel lengths, are compared with the original CFD data to ascertain the lowest possible channel length for precise correlation development. An appropriate channel length is further used for deriving correlations for sinusoidal and zigzag flow paths. The hybrid model helps determine the upper limit of the side width (fin width) of the channels based on equivalent thermal resistance between fluid and walls as the lower limit is constrained by stress criteria. The present model estimates that at least 20 rows/plates need to be modelled for the correct performance estimation of a full-scale MCHE. The minimum rate of heat loss-based stack optimization approach is implemented in estimating the optimum number of rows and stack dimensions. The channel and stack dimensions are obtained and compared for straight, sinusoidal, and zigzag flow paths for Reynolds numbers ranging from 5 × 103 to 20 × 103, ensuring a temperature pinch of 5 °C at the cold inlet. For cold inlet Reynolds number and channel diameter of 1.5 × 104 and 1.5 mm, the stack volumes for straight, zigzag, and sinusoidal channels are 1.8 m3, 1.21 m3, and 1.15 m3, respectively with sinusoidal and zigzag paths resulting in almost similar pressure drop as ∼110 Pa, 27% lower compared to the straight channel. The article presents a guideline for hybrid model implementation in designing mini/micro channel heat exchangers. [ABSTRACT FROM AUTHOR]