MINI ON-SITE ELECTROLITIC PLANT FOR SODIUM HYPOCHLORITE PRODUCTION

Transcription

1 MINI ON-SITE ELECTROLITIC PLANT FOR SODIUM HYPOCHLORITE PRODUCTION With maximum capacity of 50 g/h, which is 1.2 kg/day, of the equivalent chlorine. H50 mini can disinfect 28 l/s water and make 0.5 mg/l of the chlorine residual. TECHNICAL DATA OF HLOROGEN H50 Capacity Cl2 (kg/h): 0,05 Saturated brine solution flow 30%(l/h): 0,5 Softened water flow (l/h): 4,5 Electrolite flow (l/h): 5 Salt usage (kg/h): 0,15 Power consumption (W): 300 Electrical requirement (~V; 50Hz): NaOCl strength (%): 0,9-1 The Hlorogen H50 mini plant consists of the following components: 1. Electrolyser 2. Water softener 3. Softened water Tank 4. Salt Saturator 5. Sodium hypochlorite 1% solution Tank 6. Pumps for softened water and brine solution 7. Switching power supply 8. Hydrogen dilution with fan ventilation system 9. Microprocessor process control system Hlorogen PLC 1

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3 «Hlorogen» Basic description Water from the pipeline is filling water softener (4), calcium and magnesium ions are removed, and on the outlet of the softened water is obtained. Dosing pump (6) is transfering this water to the electrolyser where it is mixed with sodium chloride solution transfereed from tank (3) by means of another dosing pump ( tank 3 contains saturated sodium chloride solution). Eleectrochemical reaction which results in coversion of sodium chloride into sodium hypochlorite is taking place in the electrolyser cell energized by direct electric current from energetic assembly (35) of the Hlorogen device Hypochlorite solution is stored in the tank (2). Hidrogen generated by conversion reaction is let in to atmosphere by means of ventilating system (28). Optimal hypochlorite production is achieved using system automatic arrangement (36). Sodium hypochlorite solution is injected by dosing membrane pumps (38) into pipeline with water to be desinfected. Residual chlorine analyser (39) connected into regulation circuit with dosing pump keeps the concentracion of residual chlorine in the water on the predetermined level. This is providing continous production of desinfecting agent, automatic process control and automatic dosing and residual chlorine control. Full system operation can be monitored through PC (37). 3

4 1. ELECTROLYSER with capacity 50gr/h of the chlorine Modular type with the four serial connected titanium anodes and the five serial connected Hastelloy cathodes. The electrodes are activated with a precious metal oxide, have high ion-selectivity and corrosion stability. Electrolyser type is «filter press» with a plastic case. Anodes are manufacturer from the modified titanium with a precious metal oxide coating specially develop for usage in the electrolytic process with diluted brine solution with efficiency of the 95%. Cathodes are made from the stainless steel («Hastelloy» alloy) with a special coating which allows electrical power efficiency above 85% for hydrogen separation reaction, which brings a high Sodium-chlorite to the Sodium-hypochlorite conversion rate. In it's lover part, the electrolyser has the temperature sensor, which is used to shutdown the electrolysis process when temperature of the electrolyte reach it's maximum. In the electrolyser the diluted brine (3%) is converting in the diluted (1%) sodium hypochlorite solution with no chlorine in the air. 4

5 In the electrolysis process a chlorine is separated at the anode and hydrogen at the cathode. Chlorine then reacts with the electrolyte and form sodium hypochlorite. Produced sodium hypochlorite solution is transferred in the sodium hypochlorite tank. Separated hydrogen is mixed with the air and released in the atmosphere through ventilation system with fan. Electrolyser Model E50 anodes cathodes capacity ekv. Cl2 (kg/h) capacity ekv. Cl2 (kg/day) pcs. dim.(mm) material conn. pcs. dim. (mm) material conn x 50 x 2 Titanium serial 5 80 x 50 x 2 Hastelloy serial Input electrolyte NaCl (gr/l) Total electrolyte flow (l/h) Conversion index (kg NaCl/1kg Cl2) Current density (ma/cm²) Input water temperature ( C) 0,05 1,2 Allowed water hardness (mg/l CaCO3) , Working DC voltage (V) Optimal DC current (A) Switching power supply type Allowed AC voltage (V) Max. DC current (A) Optimal power consumption (kwh) 3,5 35 SP ,25 Produced solution concentration (%) Optimal electrolyte temperature ( C) Salt consumption (kg/day) Salt consumption (kg/month) *Maximal water flow with keeping residual at 0,5 mg/l which can be disinfect (l/sec) 0, ,

6 * Maximal water flow which can be disinfect with the Hlorogen H50 mini in dependence of the chlorine need and desired chlorine residual. Chlorine need (mg/l) Desired chlorine residual (mg/l) Chlorine consumption (g/min) NaOCl consumption (ml/min) Chlorine consumption (g/h) NaOCl consumption (l/h) Maximal water flow (l/s) 0 0,3 0, ,7 4, ,4 0, ,5 0, ,1 0,5 0, ,7 4, ,2 0,5 0, ,3 0,5 0, ,9 17 0,4 0,5 0, ,6 4, ,5 0,5 0, ,6 0,5 0, ,5 4, ,7 0,5 0, ,5 4, ,8 0,5 0, ,8 4, ,9 0,5 0, ,5 0, ,6 4,86 9 Production of the E125 m electrolyser, which is 50 g/h or 1.2 kg/day equivalent chlorine, is enough for disinfection of the 28 l/s water with sustain free chlorine residual at 0.5 mg/l. 6

7 2. WATER SOFTENER The makeup water used for the salt saturator and feed water used for the dilution of the brine solution must have less than 17mg/l of CaCo3 hardness, otherwise operating efficiency and maintenance free operation will be compromised. For water supplies with hardness greater than 17mg/l of CaCO3, a water softener is required. For softening a supply water, the ion change filter (softener) is used, which consists from the ion-change cylinder filled in with the ion-change mass, which hold on a calcium and a magnesium ions and change them with a sodium ions, and that makes a water to became soften. When the ion-change mass become exhausted and it need to regenerate with the saturate brine solution. Ion-change cylinder capacity must be enough for four to five days of continuous work, after which it needs a regeneration with one and a half hour duration. Saturated brine solution, used for regeneration process, is spilled to the drain. Technical data of K180/8 Water Softener Ion-change cylinder: composite Type: K180/8 Cylinder dimension (R x h): 160 x 500 mm Cylinder capacity (l): 10 Type of ion-change mass: Lewatit S100 ion-change mass capacity (l): 8 Case: Process control: PEHD Hlorogen PLC Water inlet ("): 1/2 Flow (l/h): 10 Capacity (m3x1 n) 28 Working temperature ( C): 4-35 Working pressure (bar): 2,5-5 Regeneration remedy: Saturated brine solution Salt consumption (kg): 2 Dimension (W x H): 180 x 650 mm 7

8 *Number of working hours in relation with the water hardness, for the water softener with 8 liters of the ion-change mass and 10 l/h average water flow. Water hardness in German degrees ( dh) Water hardness in (mg/l CaCO3) No. of working hours between two regeneration processes (h)

9 3. SOFTENED WATER TANK TECHNICAL DATA OF SOFTENED WATER TANK Tank type: Tank dimensions (W x D x H): ROMH50/ x 160 x 355 mm Capacity (l): 5,5 Case: PEHD Water connections ("): 1/2 Drain connections ("): 1/2 Level control: Process control: Level indicator Hlorogen PLC Softened water tank store the softened water from the water softener and fed Pump P2 (metering pump for softened water) to the electrolyser where it is mixed with saturated brine in 10:1 solution. 9

10 4. SALT SATURATOR The salt saturator creates the brine solution that feeds the electrolyser. This is created by passing the make-up water through the salt bed forming a 30% saturated brine solution which is then fed by brine metering pump P1 to the electrolyser. Typically the saturator is sized for 30 or more days production to ensure sufficient salt quantity to provide production continuity and economical refill cycles. Provided salt saturator with a capacity of 450 kg of the salt, for 30 or more days production. Salt saturator contain moisten salt and above it is saturated brine solution. This solution is filled through inlet basket and solenoid metering pump into the electrolyser. Also it is used for regeneration of the water softener. Solution for the electrolytic process (3% of NaCl) is created mixing exact quantity of softened water and the saturated brine. Salt saturator should be refilled with the salt when it is signalized on the display or on the PC monitor. It has the indicator of the minimum salt level, which signalizes when refilling with (pure 99.8%) salt is needed. Salt saturator also has a level indicator for automatic refilling with the softened water. When the salt level drops to the minimum, solenoid valve for refilling the salt saturator with the softened water closes water supply. SALT SATURATOR TECHNICAL DATA Tank type: Dimensions (R x H x d ): RSH50/ x 1500 x 10 mm Tank's capacity (l): 400 Salt capacity (kg): 450 Level indicator: Tank's material: IC PEHD Water inlet ("): 1/2 Drain outlet ("): 1/2 Saturated brine outlet ("): 1/2 Max. refill capacity (kg): 135 Continuous production (days) 30 Softened water level control: Process control: level indicator Hlorogen PLC 10

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12 5. SODIUM HYPOCHLORITE TANK Sodium hypochlorite solution, generated in the electrolyser, flows to the (working) sodium hypochlorite tank, from which, through the automatic metering system, is injected in the treated water. Tank has a two level indicators which are connected with the Hlorogen PLC. That two level indicators are: the maximum level indicator and the minimum level indicator. When a hypochlorite level reaches the maximum level in the tank, the electrolytic process is shut down, and when a hypochlorite level fall to the minimum level, the electrolytic process is continued. The working autonomy on maximum consumption of the sodium hypochlorite is 3.5 days for a tank with capacity of 400 liters. The autonomy can be extended with adding one or more extension tanks. SODIUM HYPOCHLORITE TANK TECHNICAL DATA Tank type: Dimensions (R x h x d ): RNHH50/ x 1500 x 15 mm Tank capacity (l): 420 Sodium hypochlorite capacity (l): 400 Tank material: PEHD NaOCl inlet ("): 1 Drain outlet("): 1/2 NaOCl outlet ("): 1 Working autonomy(h): 74 Max. level of NaOCl control: Min level of NaOCl control: Process control: level indicator level indicator Hlorogen PLC 12

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14 6. PUMPS FOR SOFTENED WATER AND BRINE SOLUTION Meterig pumps for the softened water P2, and the saturated brine P1, feed the electrolyser with the softened water and the brine, which are mixed, creates 3% diluted brine solution, which is used in the electrolytic process. P1 pamp feeds the electrolyser with 0.5 l/h of the saturated brine. P2 pump feeds the electrolyser with 4.5 l/h of the softened water. Summary flow through the electrolyser is 5 l/h of an electrolyte. Metering pumps P1 and P2 are positioned on the hydraulic bord. Each pump in the system has the S100 flow sensor, which gives real-time information about a flow. If real flow (measured by the flow sensor) is not same as expected on the pump, the system would be shut down. TECHNICAL DATA OF P1 PUMP FOR SATURATED BRINE Pump type: Diaphragm type: Material: Capacity (l/h): Case: Solenoid diaphragm pump for aggressive media PTFE MTM Head PEHD, Valves PEHD 0 5 (at 5 bar) Aluminum Inlets ("): 1/2 Power supply (AC): 220 V, 50 Hz Power (W): 40 TECHNICAL DATA OF P2 PUMP FOR SOFTENED WATER Pump type: Diaphragm type: Material: Capacity (l/h): Case: Solenoid diaphragm pump rubber MGM Head PEHD, Valves PEHD 0 15 (at 2 bar) Aluminum Inlets ("): 1/2 Power supply (AC): 220 V, 50 Hz Power (W): 40 14

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16 TECHNICAL DATA FOR SIGMA 100 FLOW SENSOR Sensor type: Material: Flow sensor for aggressive media Acryl Capacity (l/min): Case: Acryl Inlets ("): 1/2 16

17 7. SWITCHING POWER SUPPLY Supply electrolyse with the low voltage (3.5 V) DC current (35 A). Switching power supply's basic caracteristics: It is supplied from mains AC 220 V, 50 Hz. DC electrolytic current stays constant (35 A) when the mains voltage has variations from 90 to 260 V. Switching power supplies supply all equipment (electrolyser, pumps, valves, ventilation, process control, signalization, etc.). All elements are situated in the enclosure. Connections with the mains power and the equipment are made with a electric wires with plastic insulation resistant on aggressive media. All processes are fully automatic and controlled. All necessary protection measures are used. TECHNICAL DATA FOR SWITCHING POWER SUPPLY Type: SP Mains (AC V): Max. mains current (AC A): 5 Typical mains current (AC A): 1,2 Case: Steel enclosure Output voltage (DC V): 5 Output current (DC A): 55 Connections: Screw terminal block Over load protection: % Working temperature ( C): 0 50 Dimensions (W x D x H mm): 115 x 230 x 50 17

18 8. HYDROGEN DILUTION WITH FAN VENTILATION SYSTEM This system is specially designed for dilution of the hydrogen, which is produced in electrolytic process, and it's releasing to the open air. Specially designed fan blows fresh air in the electrolyser and mix it with the hydrogen. Hydrogen is diluted to max. 10% of Lower Explosion Level, and then is released in the open air. If ventilation system is not working the electrolytic process can not start or it is shut down. TECHNICAL DATA FOR THE FAN Type: TD 160/100 N Power supply (AC V): 230 Current (AC A): 0,15 Power (W): 23 Case: Reinforced plastic Nominal speed (rpm): 2100 Max. air flow (m³/h): 130 Noise level (db): 14 Max. pressure (Pa) 50 Max. working temperature ( C): 40 Dimensions (R x H mm): 151 x 232 Protection: IP44 18

19 9. MICROPROCESSOR PROCESS CONTROL SYSTEM HLOROGEN PLC PROCESSOR CONTROL UNIT WITH PERIPHERAL DEVICES: Central processor unit, in communication with the peripheral processor units, sensor and actuators, makes the process control system. Processor system is based on ATMEL AVR with special designed software which is designed by the expert team. Provided in the beginning of development, optional output for a connection to the standard PC (connector for serial port RS232 communication with the special PC computer and application software) during exploitation shows like necessary for proper functioning of the equipment and in the later design it becomes part of the system. PC COMPUTER FOR CONTROLLING AND MONITORING: Provide monitoring of the all process parts with the proper measured values (analog, digital or descriptive) in the tables, diagrams or charts. Also automatic printing can be set printing of the measured values and the system states, one or more times during a day or defined time interval. The special sub-program is designed for direct access to the system controls and editing of the all system parameters. This part of software is protected with the password. Software application is working under Microsoft Windows XP operating system. GSM/GPRS COMMUNICATION: System is equipment with the GSM modem for communication through the GSM network. GSM modem is an integral part of the processor control unit and the GSM communication does not need a PC computer for it's proper operating. GSM/GPRS communication characteristics: Communication through the SMS or data transfer through the GPRS. SMS Communication: When a user password is received, the system transmits all relevant parameters (INFO-TEST MODE) to that user. If occurs the system alarm or some other defined event in the system operation, the system would inform, through SMS, user or central PC. User can define a phone numbers: on which the system would send a alarm information, permit ban authorization to communication, and with additional protection measures, direct control the system operation through SMS. GPRS Communication: Using this way of communication enables data file's transfer with all relevant system parameters at definite time period and capability of sending data through internet on definite IP address. SOFTWARE LICENCE: System software (µc+pc software) have been developed trough long years period by expert team work. It is developed by using modern software tools, and it is ownership of producer «SIGMA-Kula» with all rights reserved. All unauthorized usage, coping of this software or any its part is protected by copyright law and international treaties. 19

20 MONITORIG, MEASURING AND CONTROL Processor control unit monitor and control complete technological process with internal communication with a other regulating units and the PC. On the text display the process state, measured values and active alarms are showed. Microprocessor process control unit and communication with the PC make the closed technological process control system. ALARMS: 1. safety salt minimum 2. insufficient air flow 3. current beyond limits 4. voltage above limit 5. insufficient softened water flow 6. insufficient saturated brine flow 7. maximum hypochlorite level 8. minimum hypochlorite level 9. temperature beyond limits 10. salt minimum 11. Water pressure beyond limits REMARK: Because your demand, which you send in your at February this year, we consider usage an alternative power supply through a power conversion solution.. 20

21 EXAMPLE HLOROGEN 50gr & AUTOMATIC DOSING SYSTEM EQUIPMENT ARRANGEMENT IN THE CONTAINER 21

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