Direct Air Cooled Condenser

Direct air-cooled condenser (ACC) is a type of heat exchanger commonly used in thermal power plants. It is designed to convert steam from the turbine exhaust into water, which can then be returned to the steam cycle. Unlike a conventional water-cooled condenser, a direct ACC uses air as the cooling medium, allowing for more compact design and reduced water usage. The steam is fed through a series of finned tubes, where it is cooled by the flow of air, which is generated by a forced draft fan. It is suitable for power plants in water-deficient regions or power plants with high final temperature of condensed medium.

Operating Principle of Direct Air Cooled Condenser (ACC)

It is a cooling system in which air is used as the cooling medium and the steam from the steam turbine's exhaust is immediately condensed into water through the tube bundle of the air-cooled condenser. Its air-cooled condenser, air supply system, support structure, exhaust duct system, condensate collecting system, vacuum-pumping system, cleaning system, electrical system, and instrument control system are the primary components of its heat exchange system.

 

Single row Tube

The single row Tube made of aluminium-clad flat tubes and aluminium wavy finned tubes by brazing, they are compactly brazing together with a bigger welding angle on the bottom.
Features of the single row tube are as follows,

  • Great heat transfer performance

    Bigger flow area on steam side, less pressure loss, higher heat transfer efficiency; Raised aluminium rolled fins reinforce heat transfer performance by increasing heat transfer area and enhancing air turbulence.

  • Great Anti-corrosion Performance

    Tubes and fins are completely covered by aluminium and compactly brazed together, ensuring great anti-corrosion performance

  • High strength

    High strength tubes not only facilitate transport and installation, but also endure high pressure cleaning.

  • Great Anti-freezing performance

    Tube section is with bigger length-width ratio, which reduces possibility of condensate overcooling and tube freezing in winter.

 

Product Structure of Direct Air Cooled Condenser (ACC)

Main components

  • Air Cooled Condenser
  • Air Supply System
  • Exhaust Duct System
  • Condensate Collection System
  • Vacuum-pumping System
  • Cleaning System
  • Electrical System
  • Instrumentation and Control System
  • Support Structure

 

Maintenance Of Industrial Air Cooling Systems

  • Regular cleaning of air filters to ensure proper airflow and prevent clogging.
  • Inspection and cleaning of evaporator and condenser coils to remove any accumulated dust or debris.
  • Lubrication of fan bearings and motors to ensure smooth operation.
  • Inspection of electrical connections, wires, and controls for damage or wear and tear.
  • Checking of refrigerant levels and ensuring there are no leaks.
  • Regular inspection of refrigerant lines for any damage or corrosion.
  • Cleaning and inspection of drain pans to prevent the buildup of algae and bacteria.
  • Inspection of ductwork and insulation to ensure proper airflow and prevent leaks or damage

 

Features of Direct Air Cooled Condenser (ACC) 

  • High thermal efficiency

    Direct air-cooled condensers (ACCs) have a high thermal efficiency due to their finned tube bundles and large airflow, which allows for efficient latent heat transfer and ensures that the entire steam turbine exhaust is condensed.

  • Compact size

    ACCs are designed to be compact and take up less space compared to conventional water-cooled condensers, making them suitable for installation in power plants with limited space.

  • Reduced water usage

    ACCs do not require any water from an external source for cooling, making them more water-efficient than traditional water-cooled systems. This reduces the impact of the plant on the environment and results in potential cost savings for the power plant.

  • Reduced maintenance

    ACCs have a simplified design and require less maintenance than water-cooled systems. There is less need for water treatment or mitigation systems to prevent leaks or corrosion, reducing maintenance costs for the plant. As a result, ACCs have higher reliability and less downtime, which helps reduce operational costs.

 

Advantages of Direct Air Cooled Condenser (ACC)

There are several advantages of using a direct air-cooled condenser (ACC) in a power plant:

  • Reduced water usage

    As they do not require any cooling water, ACCs offer significant water savings compared to traditional water-cooled systems. This can help power plants meet environmental regulations and reduce their impact on the environment.

  • Compact design

    ACCs are designed to be compact and require less space than traditional water-cooled systems. This makes them ideal for use in power plants with limited space and allows for easier installation.

  • Lower maintenance costs

    ACCs require less maintenance than water-cooled systems and have a simplified design, reducing maintenance costs and improving plant reliability.

  • No water treatment required

    Water-cooled systems require water treatment to maintain water quality and prevent corrosion. Since ACCs do not require cooling water, there is no need for water treatment or the associated costs.

  • Efficient operation

    ACCs have a high thermal efficiency due to their finned tube bundles and large airflow, resulting in efficient latent heat transfer and ensuring that the entire steam turbine exhaust is condensed.

  • Its single-row large flat tube bundle features excellent heat transfer performance. Its main features include high heat transfer efficiency, strong corrosion resistance, high strength for transportation and cleaning, and good antifreeze performance.

  • Manufacturing advantages

    We have the latest single-row tube production line, including numerical control fin production equipment, numerical control tunnel brazing equipment, tube bundle welding equipment, and pressure test equipment, which are controlled by the latest computer hardware configuration and professional software. It can effectively improve production efficiency and control product quality, with an annual production capacity of 4x600 MW air cooling tube bundle.

  • Service advantages

    The company has a competent service team for on-site installation guidance, operation debugging and after-sales service. They are always ready to provide clients with professional technical guidance and services, timely handle the problems found in operation, perform all quality assurance within the warranty period in strict accordance with the contract. The company can provide all-round, whole-process and life-cycle technical services with reliable system design and professional team to ensure the economic operation of the air-cooling system and create value and profit for clients.

In summary, the main advantages of using a direct air-cooled condenser (ACC) in power plants include reduced water usage, a compact design, lower maintenance costs, no water treatment requirement, and efficient operation.