Training Session

One

Basic Process Technology

Industry Background System
Requirements An ECP (Electrochlorination Package)
Clients Main Equipment
Seawater Pumps
Basic Process Chemistry
Seawater Filters (Strainers)
Seawater Electrolysis
Brine Electrolysis Electrolysers
By-products Transformer Rectifiers
Degassing Storage Tanks
Company Products Hydrogen Dilution
Panclor Electrolysers
Hypochlorite Dosing
(Plate Cell)
Elchlor Electrolysers Acid washing
(Concentric Tube Cell) Instrumentation Package
Natclor Electrolysers MCC / Control Panel
(Brine Unit)
System Sizing
Main Electrolyser Services
Seawater Carrier Stream
Transformer Rectifiers
The main purpose of an Electrochlorination system is to remove the biological
content from seawater, or rather to discourage the growth of marine organisms
within seawater systems, i.e. render it a hostile environment

Marine organisms can be split into two major categories commonly referred to
as biofouling.

Macro Organisms
Mussels
Clams
Barnacles
Hydroids
Oysters
Grass

Micro Organisms Bacteria

Slime
Algae
An ECP generates Sodium Hypochlorite by the electrolysis of either seawater or a
brine solution.

Sodium Hypochlorite is a Chlorine equivalent and as such is an effective biocide for

water treatment.

Sodium Hypochlorite in the domestic environment is commonly called Bleach and is

typically at a concentration of 3.5%, the Sodium Hypochlorite produced by
electrochlorination of seawater is at a concentration is 0.1 0.2% and by Brine systems
up to 0.8%.

Both concentrations are highly corrosive and materials will be included in detail in later
training sessions
The use of seawater is largely, but not
completely, for heat transfer from another
process. If marine organisms are allowed to
colonise a seawater system their presence
will be detrimental to both the heat transfer
process and significantly reduce the
seawater system efficiency. The use of
Sodium Hypochlorite Dosing to the seawater
systems ensures their cleanliness and
maintains their design efficiency, absence of
seawater treatment would increase
operating costs, render the system
inoperable within a short period of time and
elevate the rate of corrosion of the system
components.
Stating the obvious but seawater systems,
and the ECPs, are located in coastal areas,
offshore or in the marine environment
(Shipping).
Another application for ECPs, typically
offshore, is for treatment of Water Flood or
Water injection. This is an oil industry process
where seawater is injected into an oil well to
force the residual oil from an otherwise
pressure exhausted well. The seawater
injected has to be sterile to ensure the
marine organisms do not thrive in the warm
environment and block up the oil bearing
strata. Part of the sterilisation process in
chlorination.
Natclor or Brine systems are used where
seawater is unavailable and is essentially the
same electrochlorination process utilising
artificially produced brine (seawater). A
benefit of this system is that it can also be
used to treat Potable water whereas
seawater systems can not
Land Based

Power Stations
Desalination Plants
LNG Facilities

Offshore

Oil Rigs
FPSOs (Floating Production and Storage a drilling ship)

Shipping

CEL does not at present supply to this industry.

Typically FEED contractors in the early stages of
new builds.
(Front End Engineering and Design)

Budget and outline technical proposals against a

Specification in anticipation that our proposals are
used in the later stages of the bid process.

Then EPC contractors.

(Engineering Procurement and Construction)

These are the contractors that follow on from the

FEED stage of a new build. This is where CEL again
bid the ECP element of their contract and if
successful with whom CEL progress the Detailed
engineering and construction to a Successful
commissioned ECP.
Electrolysis is the process of passing a DC electric current through an electrolyte,
in our case seawater or brine.

The formation of sodium hypochlorite in an electrochemical cell is a mixture of

chemical and electrochemical reactions.

Electrochemical
at the anode 2 Cl Cl2 + 2e (Chlorine)
at the cathode 2 H2O + 2e H2 + 2OH (Hydrogen)

Overall the process can be considered as :-

NaCl + H2O Electrolysis NaOCl + H2

In the main the other reactions include the formation of Hydroxides of Magnesium
Mg(OH)2 and Calcium Ca(OH)2 at the Cathode.
The capacity of an ECP should meet or exceed the Sodium Hypochlorite demand for the seawater system to be
treated.

This Chlorine (Hypochlorite) demand is dependent on the flow through the main seawater system and the
biological Chlorine demand of that seawater, whilst achieving the minimum Chlorine residual in the seawater at
the outfall or return to sea.

Some typical seawater Chorine demand values are as follows CEL have to comply.

Location Chlorine Demand (30 min)

North Sea 0.9 to 1.25 mg/l

Gulf, 1.4 mg/l
Pacific Ocean 0.05 to 0.1 mg/l
Coastal China 0.7 to 2.0 mg/l
Virgin Islands 0.9 to 0.6 mg/l

These values would be included with an allowance for example of 0.5 mg/l for the
residual in sizing an ECP, however this dosing regime is the responsibility of clients
in the preparation of their requisitions / specifications with which CEL have to
comply.
 Chemical Symbol mg/I
Chloride Cl 19,350
Sodium Na 10,750
Sulphate SO4 2,700
Magnesium Mg 1,290
Calcium Ca 410
Potassium K 380
Bicarbonate HCO3 140
Bromide Br 65
Strontium Sr 13
Aluminium Al 1.9
Silicon Si 1.1
Fluoride F 0.8
Nitrate NO3 0.8
Boron B 0.4
Barium Ba 0.2
Iron Fe 0.1
Manganese Mn 0.1
Copper Cu 0.1
Lithium Li 0.1
Phosphorous P 0.06
Iodide I 0.04
Silver Ag 0.02
Arsenic As <0.01
Nitrate NO2 <0.01
Zinc Zn <0.01
Total mg/l 35,000
 An important quality of the seawater used as an
electrolyte in electrochlorination is its electrical
conductivity. The electrical conductance is a
function of both the chemical composition and Total Chlorine =
also the temperature. The lower the salinity the
lower the conductivity of the media, high and Combined Chlorine + Free
low temperatures decrease the conductivity Chlorine
with the optimum temperature being
approximately 20 Deg C. It is the Free Chlorine that is the active component
and importantly it is that value that must be
Chorine can be present in two forms, Combined
and Free, and it is the Free Chlorine that is the measured as the process system residual.
effective component in controlling biofouling.
Combined Chlorine is that proportion of the
dosage that has been consumed (Chloramines).
 Magnesium and Calcium Hydroxides as by-products are
Management of the by-products of the insoluble in seawater but which in the main are carried
electrolysis of sweater will be detailed later in the
Training Programme however it is worth spending some away through the ECP system through the maintenance
time on the basic chemistry involved at this of appropriate velocities in the pipe lines and latterly
stage. discharged to sea.
The by-products include
These Hydroxides however naturally adhere to the
Hydrogen 316l / kg NaOCl cathodes unless prevented from doing so by high media
turbulence within the Electrolyser.
Magnesium Hydroxide Mg(OH)2 Elchlor Electrolysers of tubular construction achieve this
Calcium Hydroxide Ca(OH)2 turbulence however the larger plate type Panclor
Electrolysers can not.
Hydrogen management is achieved by dilution with air in
what is called a Degassing Tank with no chemistry To avoid excessive build up of the Hydroxides within the
involved.
Panclor Electrolysers they are periodically removed from
This will be a separate service and washed with a dilute solution of Hydrochloric
subject later in the Training Programme. Acid (HCl) 5-7%.
Acid + Alkali Salt + Water
These salts are soluble and form a solution.
Insoluble by-products of the electrolysis
process include
The weakened acid that remains after cleaning is
neutralised using Sodium Hydroxide.
Magnesium Hydroxide
Mg(OH)2
HCl + NaOH 2NaCl + H2O
Calcium Hydroxide
The forgoing is the basic chemistry involved in the
Ca(OH)2
ECP process, there are numerous other reactions
that take place which are essential knowledge to
When Hydrochloric Acid, HCl, is exposed to these
academia however for mainstream ECP
hydroxides the following reactions take place.
engineering, experience has shown, the forgoing
is adequate for most purposes.
2HCl + Mg(OH)2 MgCl2 + 2H2O

2HCL + Ca(OH)2 CaCl2 + 2H2O


In certain applications seawater generated Sodium
Hypochlorite may not be appropriate due to
geographical location or perhaps purity where
Potable water is to be dosed from this source.
Therefore the Electrolyte (Brine) has to be
manufactured as a feedstock for the ECP. This
achieved by the use of a salt saturator, essentially a
tank which is filled with Towns Water and into which
is loaded commercially available Sodium Chloride
NaCl, essentially food grade table salt in bulk.
Pure Dried Vacuum Salt is ideal for a wide range of
applications including food, water treatment and
chemical manufacture. The manufacturing plant
should be registered for food production, and
accredited to the BRC Technical standard, whilst low
sulphate, bromide and moisture levels contribute to
the high chemical purity which is required for most
industrial applications.
Typical Salt Analysis
All values except moisture are calculated on a dry
basis. Test methods used are BS998:1990 or
equivalent, except appearance which is a visual
assessment.
 PROPERTY UNIT SPECIFICATION TYPICAL
ANALYSIS
Appearance White Crystalline
Assay %m/m NaCl 99.9 >99.9
Surface Moisture %m/m H2O 0.05 0.01
Insoluble matter mg/kg <50 <10
Alkalinity mg/kg Na2CO3 <150 88
Sulphate mg/kg Na2SO4 <500 180
E 535, Sodium HexacyanoferrateII mg/kg <15 6.9
Na4Fe(CN)6
Total Iron mg/kg Fe <5 2.0
Total Calcium mg/kg Ca <20 3.0
Total Magnesium mg/kg Mg <5 0.06
Total Copper mg/kg Cu <0.2 0.02
Total Arsenic mg/kg As <0.2 <0.2
Total Lead mg/kg Pb <0.05 0.01
Total Cadmium mg/kg Cd <0.1 <0.001
Total Mercury mg/kg Hg <0.05 <0.03
Total Bromide mg/kg Br <120 105
Oil* mg/kg <4 1.6
The Electrolysis of seawater or brine is most
efficient when the salinity of the media is
approximately 3.5%.

A saturated brine solution from the Salt

saturators however is considerably more
saline at 29% and has to be diluted to 3.5% in
a further supply of Towns water to be suitable
for the electrolytic generation of Sodium
Hypochlorite NaOCl.
Therein after the formation of sodium hypochlorite
in the electrochemical cell is a mixture of chemical
and electrochemical reactions similar to the forgoing
seawater example..
A benefit of a Brine system is that the purity
of the electrolyte is such that the only by-
Electrochemical
product of the Electrolysis is Hydrogen.
at the anode 2 Cl Cl2 +2e (Chlorine)
Therefore there are no insoluble salts
at the cathode 2 H2O + 2e H2 + 2OH
generated to adhere and mask the Cathodes
(Hydrogen)
and the Sodium Hypochlorite can therefore
be produced at higher concentrations up to
Overall the process can be considered as :-
0.8%.
NaCl + H2O Electrolysis NaOCl + H2
Consequently the absence of chemical
impurities negates the need of acid washing
the Electrolyser cells and true continuous
operation is possible.

By-products
Magnesium Hydroxide
Calcium Hydroxide
Hydrogen

Calcium and Magnesium Hydroxide are applicable only to
seawater ECP plate type systems and we have discussed how
these deposits can be removed from Electrolyser cells by
washing with Hydrochloric Acid.
The greatest proportion of these insoluble salts is returned to
sea by the maintenance of adequate line velocities to prevent
their precipitation in the pipe lines.
Typically a velocity between 0.75/sec and 3m/sec with a
target of 1.5m/sec prevent any precipitation and
consequential blockage of Hypochlorite dosing lines.
This design parameter does not apply to seawater prior to
being electrolysed.
Hydrogen as a by-product is not chemically treated, it is
diluted in air in a degassing tank into which the electrolyser
streams discharge the seawater carrier stream of hypochlorite
solution and the entrained hydrogen produced during
electrolysis.
Hydrogen is a flammable gas with all the attendant hazards
which have to be managed during its disposal.
The Lower explosive limit (L.E.L) for hydrogen is 4.1% in air
and consequently it is essential to keep the hydrogen mixture
in the degas tank below that level.
As design criteria the Hydrogen gas in the degassing tank is
diluted by forced draught air to less than 1% concentration.
This is achieved by blowing air into the top of the tank where
the resulting gas is evolved.
The mixture is blown out of the tank and ducted to a safe
dispersal point and exhausted to atmosphere.
 Hydrogen evolution during
Electrochlorination
The hydrogen evolution is derived
using the maximum power supply
amperage available in conjunction
with the generator configuration.
The Cathode reaction is:
2H+1 + 2e-1 H2
Therefore, the electrochemical
generation of 1g-mole of hydrogen
requires 2 Faradays.
By definition;
1 Faraday = 96, 500 Coulombs = 96, 500
A-s = 26.81 A-h
1 g-mole H2 occupies 22.40 litres at 0C
and 750mm Hg
1 g-mole H2 occupies 24.04 litres at 20C
and 750mm Hg
If the maximum power supply current
output is Imax amps, and each
electrolyser stream contains C cells, then

the maximum volume of hydrogen

produced is equal to:
This can be summarised as 316l/kg NaOCl

1.32 0.84

Electrochemical Equivalent Electrochemical Efficiency

This is the CELs Plate Type electrolyser is used for
large capacity ECP projects.

Panclor electrolysers consist of tubular bodies

horizontally mounted with the seawater entering
the electrolyser through the lower nozzle, the
inner electrode carrier of a hollow rectangular
section confines the seawater (electrolyte) flow
for maximum exposure of the media to the carrier
enclosed electrode surfaces.

The electrodes are of Titanium with the Cathode

uncoated however the Anode is coated with either
MMO or Platinum as Titanium can not operate as
an Anode and would rapidly suffer electrolytic
decomposition.

CEL coats the Anodes with sufficient plating for an

expected life of 7 years and a pro rata guarantee of
5 years.
Individual Electrolysers range in capacity
from 1kg/h to 20kg/h.

Up to four Panclor electrolysers can be

installed in one hydraulic and electrical series and
any number of streams can be installed in parallel
to accommodate any client chlorine demand.
Cathode Bipolar Electrode Anode

Panclor plate type electrolyser plate electrodes are interleaved, the Anode shown here in red is connected to the DC power
supply and the cathode shown in black is connected to the negative of the DC power supply.

By passing an electrolyte between the electrodes a series of electrochemical cells is created by virtue of the bipolar intermediate
electrodes. When DC current is applied the potential difference (Voltage) makes the bipolar electrodes anodic at one end and
cathodic at the other.

In a Panclor electrolyser there are 10 cells and the DC current therefore passes through the electrolyte 10 times as it itself passes
through the electrolyser. The electrolyte gradually increasing in hypochlorite concentration as it progresses. Similarly the by-
products increase as a function of the repeated electrolysis.

As we discussed above the electrolyte (seawater) velocity and turbulence through this type of electrolyser is not sufficient to
scour the cathode surface of the hydroxides generated. Therefore these electrolysers need to be periodically washed with dilute
Hydrochloric Acid. To permit this cleaning and maintain Hypochlorite productivity a redundancy is normally include in the
generating capacity of the ECP, e.g. 3 x 50% Electrolyser streams.
This is the CELs Concentric Tube Type electrolyser and is used for smaller capacity ECP projects, typically offshore
installations.

Elchlor Electrolysers consist of an outer Cathode Titanium tube and an inner Anode Titanium Tube coated with MMO or
Platinum to the same criteria as the Panclor electrodes discussed previously.

Mounted vertically the seawater flow through the Elchlor Electrolysers annular gap exhibits a very high turbulence which
effectively scours the cathode surface such that the hydroxides do not adhere

The consequence of this feature is that the Elchlor Electrolysers can be operated on a true continuous duty and do not
require acid washing. Considering the handling and logistics of managing Hydrochloric acid offshore this is an attractive
feature for the installation of Elchlor Electrolysers.
Seawater has to supplied to an Electrolyser stream in which it is to be electrolysed and produce the
Sodium Hypochlorite. This seawater stream can best be described as a carrier stream and the
concentration of hypochlorite produced is relatively weak at 0.2% maximum. Most of the salt (Sodium
Chloride) which enters the system as a constituent of seawater remains as salt at approximately 3.5%.

For each application there is a calculated flowrate of seawater based on achieving the design
concentration of the ECP. This is an important feature and the flows are monitored by their respective
instruments. Part of the power losses in an electrochemical process is in the generation of heat in the
electrolyte and an excessive increase in temperature would be detrimental to both the process and to
the materials of construction.

ECP installations benefit from a controlled mass balance, i.e. seawater entering the system balanced
with the Hypochlorite solution dosed back into the main seawater system. The seawater is generally
supplied from the system being treated and dependent on the quality of this utility booster pumps,
strainers, and pressure control valves may be installed to accommodate the stable supply requirements.
Transformer Rectifiers are an important item of major equipment. The electrolysis process is
dependent on DC current whereas utility supplies are AC.

The electrolytic process typically operates at much lower voltages than utility supplies but at very
high current. The Transformer section achieves this for the AC component of the utility supply
where the Rectifier section, by the use of thyristors and control equipment, rectify that low
voltage high current AC to low voltage high current DC.

The control of the DC current (Amps) to the electrolysers is the ECP productivity control, usually
able to adjust the output between 10% and 100% with a consequent raising or lowering of the
hypochlorite concentration in the seawater carrier stream.
Seawater Pumps
Generally two seawater booster pumps are installed in an ECP, operating on a duty standby basis. These pumps will be
rated to supply all the seawater demands including a defoam spray on the Degassing Tank and strainer back wash
cleaning requirement.

Seawater Filters (Strainers)

On site seawater utility supplies are generally subject to coarse straining for the main seawater system. The ECP has
process components which are not tolerant of large particle sizes therefore the seawater supply is further filtered down
to 500 microns. Again there are typically two strainers installed on a duty / standby operating basis.

Electrolysers
Either Panclor or Elchlor Electrolysers will be installed, rated at the required productive capacity and typically installed
as 2 x 50% or 3 x 50% to allow for redundancy in the case of Elchlor or acid washing in the case of Panclor.

Transformer Rectifiers
Again we have discussed these main equipment items and typically they are individually installed per Electrolyser
stream. The Transformer Rectifiers are constant current controlled, i.e. we control the amperage which consequently
controls the hypochlorite output of the Electrolysers. The amperage will remain at the set point and as the seawater
conductivity varies as a function of salinity and temperature the voltage necessary to drive the amperage will
automatically adjust to suit prevailing conditions.
Degassing / Storage Tanks
The hypochlorite product, complete with entrained Hydrogen is discharged into a degassing tank. The
degassing tank is sized to retain the carrier stream for a minimum period of five minutes during which
the Hydrogen disentrains from the surface.

When part of the dosing regime includes shock dosing it is necessary to generate that weight of
hypochlorite in advance and that volume has to be stored. Therefore that maximum volume is added to
the Degassing Tank design.

To avoid the precipitation of the insoluble hydroxides in the Degassing tank the carrier stream inlet is
tangential to the circumference and the resultant stirring of the contents maintains the hydroxides in
suspension for discharge through the dosing system and back to sea.

Hydrogen Dilution
The Degassing Tank is ventilated with sufficient air, from two blowers on a duty / shut down operating
basis, to dilute the maximum Hydrogen production concentration to a safe level of 1%. The resultant air
/ Hydrogen mixture is then discharged to atmosphere
Hypochlorite Dosing
There are varieties of Dosing regimes that are available to clients and it is they who specify the regimes engineered into
an ECP. Typically either continuous or a combination of continuous and shock dosing will be applied. For each duty
there are generally installed two centrifugal pumps of 100% duty operated on a duty / standby basis.

Continuous Dosing
This is the continuous application of a low dosage rate which renders the treated media as hostile to marine organisms,
in the main they simply pass through main seawater system. Pre-existing fouling prior to dosing will be neutralised but
not necessarily dislodged or removed.

Shock Dosing
Shock dosing is used to ensure that any marine organism that has temporarily resisted continuous dosing is subject to a
larger dose of treatment. Continuous dosing is generally suspended during a shock dose period, typically 3 or 4 times a
day for periods of a to 1 hour.
Shock dosing is also favoured for RO plants where the membranes suffer as a result of continuous chlorination.

Trickle Dosing
This is where a client requires a seawater pump caisson (immersed suction area) treated while the pump is not in use.

Intermittent Dosing
This is a system developed over the last few years where continuous dosing is interspersed with dosing suspension,
typically 10 minutes dose and 10 minutes suspension.
For all forms of dosing legislative control of the discharge residual hypochlorite is becoming progressively more
stringent with typically 0.5 0.7mg/l as the maximum allowable.
Acid Washing
Acid wash facilities generally include a storage / makeup tank, circulating and disposal pumps.
This applies to the Panclor electrolysers where adequate capacity has been installed to allow an electrolyser stream to
be removed from duty for acid washing. This is the process described above where the accumulated hydroxides are
removed from the Electrolysers.

Instrumentation Package
Safe operation of an ECP requires that all operating parameters of Flow, level, pressure, voltage, temperature etc. are
monitored. To this end a comprehensive set of instrumentation is employed on each ECP to monitor design parameters.

MCC / Control Panel

The MCC (Motor Control Centre) and Control Panel are not always in a combined unit however are generally located
adjacent to each other.

MCC
An MCC is essentially a control cabinet that contains all the switch gear and controls necessary to take an incoming
electrical supply or supplies and distribute same to all main equipment. All electrical protective functions are
incorporated in the MCC to ensure safe operation of the related equipment. The fault detection equipment feeds signal
to the Control Panel in the event of a malfunction.
Control Panel
The hub of the ECP, generally equipped with a PLC (Programmable Logic Controller) and touch screen HMI (Human
Machine Interface). Herein is programmed all the control requirements for ECP start, stop and trip functions in
accordance with the ECP control philosophy. All instrumentation and MCC signals are monitored by the PLC which is
programmed with the appropriate response to any unhealthy variation in any measured parameter.
An ECP is designed to meet a clients specified Sodium Hypochlorite demand, this
demand always equates to a weight of Sodium Hypochlorite per period of time. This
demand is quoted in kilograms per hour kg/h.

CEL has a spreadsheet to appropriately size ECP systems, exploring this spreadsheet
will be included in the next Training Session. This session is targeted at appreciating
the fundamentals of ECP systems such that the spreadsheet calculations will be better
understood.

Typically a client will specify there demand by equating this to a process seawater
flowrate to be treated m3/h and the hypochlorite dosing regime required in either
mg/l or ppm. Of these two references only the mg/l can be directly translated to a
demand weight, ppm is a volumetric measurement and to be converted to a weight
must be multiplied by the specific gravity (SG) of the media.

mg/l = ppm x SG
 Ecp System sizing
It is important to ensure there is clarity on this issue as many confuse mg/l and ppm as they are generally very similar
values and the difference considered insignificant.
It is not insignificant when sizing an ECP as the potential exists of not meeting guarantee points during commissioning
of the package and contractual LDs may then apply.

The equation used to determine the productive capacity of an ECP is as follows:-

NaOCl kg/h = Seawater Flowrate m3/h x mg/l (NaOCl)

1000

Or equally expressed as

NaOCl kg/h = Seawater Flowrate m3/h x ppm (NaOCl) x SG

1000

The equation applies to all dosing regimes and is summarised over a daily requirement and averaged to give the ECP
capacity.
 Ecp system sizing example one
Seawater Flowrate 100,000 m3/h

Continuous Dosing 2 mg/l

NaOCl kg/h = Seawater Flowrate m3/h x mg/l (NaOCl)

1000
Therefore

NaOCl kg/h = 100,000m3/h x 2 mg/l (NaOCl)

1000

NaOCl kg/h = 200 kg/h

If the dosing regime is quoted as ppm

Seawater Flowrate 100,000 m3/h

Continuous Dosing 2 ppm

Specific Gravity 1.027

NaOCl kg/h = Seawater Flowrate m3/h x ppm (NaOCl) x SG

1000
Therefore

NaOCl kg/h = Seawater Flowrate m3/h x ppm (NaOCl) x SG

1000
NaOCl kg/h = 100,000 m3/h x 2 ppm (NaOCl) x 1.027
1000
NaOCl kg/h = 205.4 kg/h
Seawater Flowrate 100,000 m3/h
Total Shock Dose Demand per day
Continuous Dosing 2 mg/l (CD dosing suspended during
SD)
Frequency 24 6 = 4 per day
Shock Dosing 5 mg/l
Duration 4 x = 2 hours
Frequency 6 hours
SD Daily Demand 2 x 500 = 1000
Duration hour kg/day

Therefore Continuous Dose Demand per day

Continuous Dosing Requirement Duration 24 2 (SD period) = 22 hours

NaOCl kg/h = 100,000m3/h x 2 mg/l (NaOCl) CD Daily Demand 22 x 200 = 4400
1000
kg/day
NaOCl kg/h = 200 kg/h
Total Daily Demand 1000 (SD) + 4400 (CD) = 5400
Shock Dosing Requirement kg/day NaOCl

NaOCl kg/h =100,000m3/h x 5 mg/l (NaOCl) Average Daily Demand 5400 24 = 225 kg/h NaOCl
1000

NaOCl kg/h = 500 kg/h

In this example we have determined that an average daily
demand of 225 kg/h NaOCl is the required capacity.
Seawater Flowrate m3/h = 150 m3/h
As stated earlier the maximum concentration of NaOCl that can
be produced in a Seawater ECP is 2000 mg/l. Therefore the seawater carrier stream will be 150 m3/h.

There may however be other constraints and for this example it Therefore the seawater booster pumps will be rated at :-
will be considered that the desired product concentration is
1500 mg/l. Electrolyser requirement
150 m3/h
Therefore to calculate the seawater carrier stream the formula
Strainer Back Flush@ 10%
has to be transposed :-
15 m3/h
NaOCl kg/h = Degassing Tank Defoam
1 m3/h
Seawater Flowrate m3/h x mg/l (NaOCl)
1000 Total
166 m3/h
Seawater Flowrate
(This may be changed if minimum flow requirements
m3/h=NaOCl kg/h x 1000 mg/l (NaOCl) apply to pumps)
Seawater Flowrate

m3/h=225 kg/h x 1000 1500 mg/l (NaOCl)

ECP SYSTEM SIZING ELECTROLYSER SELECTION
It has been determined that a 225kg/h ECP capacity is
required and that capacity must be delivered as 1500
mg/l in a 150 m3/h carrier stream.
This will be a Panclor installation and to accommodate
acid washing will be supplied with adequate
redundancy to maintain 100% productive capacity..
A fairly large system therefore it would be necessary
to select the appropriate Electrolyser where the
largest capacity is 20.48kg/h each in a series of 4
Electrolysers.
Therefore
225 20.48 = 10.9 Electrolysers
This suggests a smaller electrolyser is selected that
will permit a number of streams of 4 electrolysers in
series, i.e. 3 x 4 Electrolysers streams with 12 in
operation.
Therefore
225 12 = 18.75 kg/h Electrolysers
Referring to the sizing chart the most appropriate Electrolyser selection is
the Panclor 12-19 at 1500A/m2 current density and of a capacity of 19.35
kg/h.
The current density can be reduced proportionally to achieve the desired
productivity of 18.75kg/h.
Given four Electrolysers per stream
x 18.75 = 75 kg/h per stream
The number of streams for 100% duty
225 75 = 3 Streams
Therefore to provide a redundant stream this installation will be 4 x 33%
capacity
Electrolyser Flowrate
It has been determined that the carrier stream flowrate at the specified
1500mg/l will be 150 m3/h. Therefore with 3 x 33% streams in duty the
stream flowrate will be 50 m3/h.