The Air-Cooled Condenser (ACC) represents one of the most significant technological advancements in modern thermal power generation. As the first installation of its kind in Iraq, the ACC at the Al Khairat Thermal Power Plant delivers outstanding operational efficiency while dramatically reducing freshwater demand. This article provides a detailed overview of how the ACC works, its operational benefits, and its positive environmental impact.

What Is an Air-Cooled Condenser (ACC)?

An ACC is a heat exchanger that condenses steam exhausted from the steam turbine by passing ambient air over a finned tube bundle—eliminating the need for a wet cooling water circuit. Key components include:

1. Steam Headers
   Receive low-pressure steam from the turbine outlet.
2. Condensing Tubes
   High-thermal-conductivity alloy tubes fitted with external fins to maximize heat transfer surface.
3. Axial Fans
   Pull or push ambient air uniformly across the finned tube bundles.
4. Condensate Receiver
   Collects the condensed steam (water) and returns it via feed pumps to the boiler feed system for reuse.

How the ACC Works

1. Steam Discharge: Low-pressure steam exits the turbine and enters the overhead steam headers.

2. Steam Distribution: Headers channel steam into the A-Frame tube bundles.

3. Air-Side Heat Transfer: Fans force ambient air through the finned bundles; the steam loses heat to the air stream and condenses on the tube surfaces.

4. Condensate Collection: Condensed water drains into the receiver tank, from which it is pumped back into the boiler feedwater system to complete the cycle.

Key Benefits of ACC at Al Khairat

• Air Instead of Freshwater: By relying on air as the primary cooling medium, the ACC eliminates the need to withdraw millions of cubic meters of river water—using treated wastewater only as a secondary supplementary source.
• Reduced Water Infrastructure: No large raw-water intake stations or wet cooling towers are required, significantly lowering both capital and operating costs.
• High Thermal Efficiency: The A-Frame design enhances air-side heat transfer while minimizing pressure drop, ensuring effective condensation even under high ambient temperatures.
• First in Iraq: As the inaugural ACC installation in an Iraqi thermal plant, it sets a benchmark for the industry’s transition to water-efficient cooling technologies.

Positive Environmental Impact

1. Water Conservation: Cuts freshwater usage by up to 90% compared to conventional once-through or cooling-tower systems.
2. Lower Carbon Footprint: Reduced auxiliary power demand for cooling-water pumps translates to lower CO₂ emissions.
3. Ecosystem Protection: Avoids large water withdrawals from the Euphrates River, preserving aquatic habitats and biodiversity.
4. Wastewater Reuse: Incorporates roughly 400,000 m³/day of treated municipal wastewater into the cooling cycle, easing pressure on natural water sources and promoting circular-economy principles.

The deployment of the Air-Cooled Condenser at Al Khairat Thermal Power Plant marks a transformative step in Iraq’s energy sector, combining operational excellence with stringent water-conservation and environmental stewardship. By pioneering ACC technology, the plant not only meets today’s power demands but also paves the way for future advancements in sustainable power generation.