Leading Design, Manufacture, Engineer, Supply of Water Disinfection Systems & Products
The chemical reaction is expressed as follows
NaCl +H2O+ Electricity →NaOCl +H2
The purpose of the Brine based Hypo Chlorination System “BIOCELL-B “ is to generate and Inject Hypochlorite solution into feed water to inhibit the growth of biological organism and to prevent slime deposits on the wall of circulating cooling water pipes.
The raw water is delivered to the salt water dilution tank. Here the salt is dumped manually or with the help of salt feeders. The dissolved highly saturated salt solution is pumped in to the system, here the solution is further diluted by controlled flow of fresh water.
The diluted salt water will then be passed through Hypochlorite Generators where sodium hypochlorite solution will be generated from salt water by the electrolysis process. The generated sodium hypochlorite solution will be stored in the downstream Hypochlorite Solution Storage Tanks.
Hypochlorite solution from storage tanks will then be dosed continuously as well as intermittently (shock dosing) to the intake structure. The continuous Hypochlorite dosing rate shall be controlled manually in order to maintain a level of 0.2 mg/l free of residual chlorine in cooling water discharge at seal pit. Shock chlorination has been envisaged at 5 mg/l with frequency of once every 8 hours for duration of 20-30 minutes
BIOCELL-B™ PROCESS FLOW DIAGRAM
Key Component
System Control Panel
- Mimic Panel of all components
- Electrolyzer Cell status
- System Start / Stop & Reset
- Brine Pump Status
- Brine Flow Rate
- Brine Tank usage to date
- Water Softener status
- Product Tank level
- Metering Pump status
- Chlorine Residual
- Process Alarms
Power Supply / Rectifier: Converts 415 VAC to low voltage DC to power Electrolyzer Cell(s)
Electrolyzer Cell: UV stabilized PVC body containing Titanium Anode and Nichol Alloy Cathode
Water Softener: Ion Exchange type Water Softener that removes Scaling Calcium and Magnesium Salts with non-scaling Sodium Salts preventing fouling of the cells. Provides water supply to Brine Tank
Brine Tank (Salt Saturator): Contains Raw Salt and ‘soft’ feed water. This Saturated Brine Solution is the feed to the Electrolyzer Cells
Brine Pump: Pumps the Saturated Brine Solution to the Electrolyzer Cells
Sodium Hypochlorite Storage Tank: Bulk storage of 0.8% Sodium Hypochlorite. Includes Hydrogen Vent and Ultrasonic Level Switch
Operational process
- Fill salt in the Brine Tank.
- Switch on the system in the control panel.
- Solenoid/Motorized valve will open and allow the water to flow into the system.
- Part of the water shall flow to the Brine tank to dissolve the salt.
- Adjust the water flow into the Electrolyzer with the Flow control Valve and Rotameter, as per instruction.
- The Brine dosing pump starts and injects the saturated brine solution in the water line.
- In the Electrolyzer chamber the salt solution gets converted to sodium hypochlorite
- The outlet of the Electrolyzer is connected to the Hypo storage tank.
- A blower connected to the storage tank blows away the Hydrogen, through a vent pipe.
- A temperature sensor is also provided in the Electrolyzer, if the temperature of Sodium Hypochlorite produced, exceeds the preset
- Temperature limit, sodium hypochlorite generator switches itself off giving a cooling off period for the Electrolyzer.
- A level switch provided in the Hypochlorite storage tank does not allow the production of Hypochlorite once the storage tank is full.
- It automatically switches sodium hypochlorite generator on when the level in storage tank is reduced
SALT AND WATER QUALITY
SALT – Chemical Analysis for Salt required for Electrolytic Cells
Components Minimum Values Typical Values
NaCI 99.00% 99.72%
Calcium as Ca 900 ppm 400 ppm
Magnesium as Mg 120 ppm 120 ppm
Total Sulphate 700 ppm 1200 ppm
Insoluble matter in H20 300 ppm 200 ppm
Copper as Cu 5 ppm < 0.5 ppm
Iron as Fe 5 ppm < 1 ppm
Moisture <0.2% when packed
SALT – Sieving Analysis
Mesh Size (mm): 0.6 0.42 0.21 0.15 -0.15
Typical % Retained: 12 21 31 13 23
Risk Assessment
NanoWater risk assessment program for the BIOCELL-C™ and BIOCELL-B™ technologies consider the following but not limited to:
- Internal temperature;
- Internal pressure;
- Flow rate;
- Alarm systems;
- Safety shutdown;
- Over-pressure protection;
- Gas production;
- Commissioning/ maintenance/ calibration activities;
- Power supply to electrodes;
- Proximity/ orientation to surrounding persons and equipment; and
- Raw material and chemicals handling.
Specifications
Model No. | BioCell-B 500 | BioCell-B 1000 | BioCell-B 1500 | BioCell-B 2000 | BioCell-B 5000 |
Active Chlorine Generated | 500 Grams/hr | 1000 Grams/hr | 1500 Grams/hr | 2000 Grams/hr | 5000 Grams/hr |
Salt Consumed | 2 kgs/per hour | 4.5 kgs/per hour | 7 kgs/per hour | 9 kgs/per hour | 22.5 kgs/per hour |
Hypochlorite strength | 7 ~ 8.0 Gpl | 7 ~ 8.0 Gpl | 7 ~ 8.0 Gpl | 7 ~ 8.0 Gpl | 7 ~ 8.0 Gpl |
NaOCl Produced Per hour | 70 liters | 140 liters | 210 liters | 280 liters | 700 liters |
Water that can be treated with 1 ppm of chlorine(approx.) | 500,000 liters per hour | 1000,000 liters per hour | 1500,000 liters per hour | 2000,000 liters per hour | 5000,000 liters per hour |
AC Power Consumed | 2.5kw/per hour | 4.5kw/per hour | 7kw/per hour | 9 kw/per hour | 22.5kw/per hour |
KEY COMPONENTS OF AN ELECTROLYTIC CHLORINATION SYSTEM
a) System Control Panel
- Mimic Panel of all components
- Electrolyzer Cell status
- System Start / Stop & Reset
- Brine Pump Status
- Brine Flow Rate
- Brine Tank usage to date
- Water Softener status
- Product Tank level
- Metering Pump status
- Chlorine Residual
- – Process Alarms
b) Power Supply / Rectifier
Converts 415 VAC to low voltage DC to power Electrolyzer Cell(s)
c) Electrolyzer Cell
UV stabilized PVC body containing Titanium Anode and Nichol Alloy Cathode
d) Water Softener
Ion Exchange type Water Softener that removes Scaling Calcium and Magnesium Salts with non-scaling Sodium Salts preventing fouling of the cells. Provides water supply to Brine Tank
e) Brine Tank ( Salt Saturator )
Contains Raw Salt and ‘soft’ feed water. This Saturated Brine Solution is the feed to the Electrolyzer Cells
f) Brine Pump
Pumps the Saturated Brine Solution to the Electrolyzer Cells
g) Sodium Hypochlorite Storage Tank
Bulk storage of 0.8% Sodium Hypochlorite. Includes Hydrogen Vent and Ultrasonic Level Switch
SALT AND WATER QUALITY
SALT – Chemical Analysis for Salt required for Electrolytic Cells
Components Minimum Values Typical Values
NaCI 99.00% 99.72%
Calcium as Ca 900 ppm 400 ppm
Magnesium as Mg 120 ppm 120 ppm
Total Sulphate 700 ppm 1200 ppm
Insoluble matter in H20 300 ppm 200 ppm
Copper as Cu 5 ppm < 0.5 ppm
Iron as Fe 5 ppm < 1 ppm
Moisture <0.2% when packed
SALT – Sieving Analysis
Mesh Size (mm): 0.6 0.42 0.21 0.15 -0.15
Typical % Retained: 12 21 31 13 23
CHARACTERISTICS OF 0.8% SODIUM HYPOCHLORITE
- Very Stable due to Low Concentration
- Reduced risk of decomposition to form Chlorates due to lower concentration
- Minor Total Dissolved Solids ( TDS ) Impact ( 3 PPM for every 1 PPM Dosed – equal to 12.5% Sodium Hypochlorite )
- pH of 9.0 versus 13.0 for 12.5% NaOCl
- More effective Oxidant than commercial Hypochlorite due to Oxidation Reduction Potential ( ORP ).
- Not Classed as Dangerous Goods, ( < 1% ) therefore storage bunding not required.
TECHNOLOGY DRIVER
- Improved Heat-exchanger (Boiler) Efficiency
- Instant Operation (Sodium Hypochlorite / Mixed Oxidants Generation)
- No Hazardous chemicals evolved / required
- Easy Handling, Operation, Installation & Service
- Eliminates Hazardous Material Storage
- Saves Recurring Maintenance Cost
- Avoids Break Downs and Down Time
- Custom designed Systems to fit in the available space
- Anodes used in electrolyzer cells are dimensionally stable ATMA® anodes with Precious Metal Oxide Coating
- Corrosion Proof & Self cleaning Electrolyzers Design