HTAC Water-Cooled Condenser for KAR Electrical 730MW CCPP Project

In 2017, HTAC delivered a high-performance rectangular water-cooled condenser (WCC) for the 730MW Combined Cycle Power Plant (CCPP) operated by KAR Electrical Power Production Trading FZE in Al-Rumailah, Iraq. The project, developed in partnership with Siemens AG, highlighted HTAC’s ability to design and deploy advanced condenser systems tailored to large-scale power plants in demanding environmental conditions.

Client and Site Background

• End Client: KAR Electrical Power Production Trading FZE

• Job Site: Al-Rumailah, Iraq

• Service Partner: Siemens AG

Located in Iraq’s Al-Rumailah region, the 730MW CCPP plays a critical role in meeting the region's growing electricity demands. The project required a cooling solution that could handle large heat loads while maintaining high efficiency in the desert's challenging climatic conditions.

Project Scope and HTAC’s Role

Project Requirements

The 730MW plant required a high-capacity water-cooled condenser system to meet the following challenges:

1. Heat Dissipation Efficiency: The condenser needed to handle a massive heat transfer area of 23,100m²/34,700m², ensuring optimal turbine performance.

2. Durability in Harsh Conditions: The system had to withstand Iraq’s extreme temperatures and dusty environment.

3. Environmental Compliance: Minimized water consumption and thermal pollution were essential to align with sustainability goals.

4. Seamless Integration: Compatibility with Siemens turbines and the plant’s operational framework was critical.

HTAC’s Solution

HTAC provided a custom-designed rectangular WCC optimized for the plant’s large-scale cooling requirements. The system’s design addressed both operational efficiency and environmental considerations, ensuring reliable performance in Al-Rumailah’s demanding conditions.

Key Features of the HTAC WCC

1. Massive Heat Exchange Area

• With a total heat transfer area of 23,100m²/34,700m², the WCC was designed to efficiently condense steam and maintain low turbine backpressure, maximizing power generation efficiency.

2. Rectangular Design for Space Optimization

• The rectangular configuration allowed for compact installation, ideal for the project’s site layout while ensuring ease of maintenance and inspection.

3. Durable Materials for Harsh Environments

• Built with high-grade materials to resist corrosion and wear caused by high temperatures and dusty conditions.

• Advanced sealing systems ensured reliable, leak-free operation over extended periods.

4. Efficient Cooling Water Flow Management

• The system was engineered to optimize water flow through the condenser, reducing water consumption and ensuring consistent performance even under peak loads.

5. Environmental Compliance

• With an emphasis on reducing water usage and minimizing thermal discharge, the condenser met stringent environmental regulations.

Results and Performance

Since its commissioning in 2017, HTAC’s WCC has consistently delivered outstanding results for the KAR Electrical 730MW CCPP:

1. Enhanced Turbine Efficiency:

• The condenser maintained optimal turbine backpressure, significantly improving the plant’s power generation capacity.

2. Reliable Operation Under Harsh Conditions:

• The WCC has demonstrated exceptional reliability, operating smoothly despite Iraq’s extreme desert temperatures and dust-prone environment.

3. Environmental Benefits:

• By optimizing water usage and minimizing thermal pollution, the system supports the plant’s sustainability goals.

4. Client Satisfaction:

• The end client, KAR Electrical Power Production Trading FZE, praised HTAC for delivering a durable, high-performance cooling solution on schedule.

Collaborating with Siemens AG

HTAC worked closely with Siemens AG to ensure the WCC met the exacting standards required for integration with the plant’s combined cycle system. This collaboration:

• Streamlined Integration: The WCC was designed to align seamlessly with Siemens turbines and operational protocols.

• On-Time Delivery: HTAC delivered the system as per the project timeline, ensuring smooth commissioning in 2017.

Conclusion

HTAC’s rectangular water-cooled condenser for the KAR Electrical 730MW CCPP project demonstrates the company’s expertise in delivering large-scale, high-efficiency cooling solutions tailored to unique project requirements. Through innovative design and superior performance, HTAC continues to support power plants in meeting operational goals while adhering to environmental standards.

To learn more about HTAC’s advanced condenser solutions, contact us today. Let us help you achieve reliable and efficient cooling for your power projects.