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Powell Continuous Sodium Hypochlorite Dry Chlorine Process System
Powell's Continuous Bleach Plant for Dry Chlorine and Caustic will safely produce high
quality bleach at a minimum operating cost. The system is constructed with the highest
quality components available to ensure long service life with a minimum amount of
maintenance. The plant is equipped with numerous safety devices which are intended
to shut down the system in the event of a process upset. The plant is completely
automatic and requires only that someone be available if a process upset occurs.
The systems are available in various production rates. Standard systems are rated
for 25, 50, 80, and 150 gallons per minute of 160 grams per liter available chlorine.
Each system has an adjustable production rate and is able to produce up to 200 grams
per liter available chlorine; however, the rated production rate will be decreased
slightly at strengths above 160 gpl due to the increased heat load on the system.
The bleach strength and residual caustic levels are controlled at very high tolerances
and can be adjusted at any time during production. The systems are designed for
a completely automatic operation and can be started or stopped at any moment.
Powell Continuous Sodium Hypochlorite Dry Chlorine Process Systems are completely
skid mounted on a structural steel frame approximately 20’ long x 8’ wide x 8’ high.
Bleach producers using the Powell Continuous System will considerably reduce the
man-hours required to manufacture bleach in comparison to other bleach production
processes. One operator can produce as much as 72,000 gallons of 160 grams per liter
bleach in an 8 hour day.
The continuous system also offers major cost savings in raw materials due to its
99% plus efficiency when compared with a 93-96% efficiency experienced in batch
operations. This increase in efficiency results in a decrease in the amount of sodium
chlorate produced. The
Material Balance On-Line Interactive Tool helps quantify these savings in
Due to an extremely high repeatability of the continuous system, considerable savings
are experienced from using fewer raw materials. Residual caustic levels can be lowered
and final product strengths can be closer to the producer’s guaranteed strength,
resulting in less product giveaway.
The type of cooling utilized by the continuous system also provides a major savings.
Mechanical refrigeration is typically required with other processes. The Powell
system utilizes cooling tower water for cooling resulting in considerable energy
savings, lower equipment costs, and lower maintenance costs.
Utility and Raw Material Requirements
The basic utility and raw material requirements are as follows:
- Dry liquid chlorine with a minimum pressure of 120 PSIG or dry vapor chlorine at
a minimum pressure of 60 PSIG.
- Sodium hydroxide at a minimum pressure of 80 PSIG.
- Process water (typically soft water) at a minimum pressure of 80 PSIG.
- Cooling water at a maximum temperature of 85° F.
- Instrument quality dry air at a minimum pressure of 80 PSIG.
- Three phase electricity for motors.
- Instrument quality power for control system.
Materials of Construction
All units are constructed from the best materials available to maximize the service
life of the system. Standard materials of construction are listed below. Other materials
are available upon request.
- Process water, caustic, and chlorine: Schedule 80 seamless steel pipe with 3000#
forged steel fittings.
- Cooling water: Schedule 80 PVC pipe and fittings.
- Sodium Hypochlorite: Teflon lined steel pipe and fittings in high pressure areas
and schedule 80 PVC pipe and fittings in low pressure areas.
- Sodium Hypochlorite Pump: Titanium centrifugal pump with single mechanical seal.
- Sodium Hypochlorite Recycle Tank: Steel tank with black chlorobutyl rubber lining.
- Heat Exchangers: Plate and frame style with titanium plates and EPDM gaskets.
Construction Lead Time
Construction time for a continuous bleach system is typically six months. The systems
are completely water tested and all control systems are thoroughly checked before
the system is shipped. After delivery, the purchaser must make all raw material
and electrical connections. After these connections are made, Powell technician(s)
will perform additional water testing, startup, and training. Startup is typically
performed in a relatively short time since the unit is completely tested at the
Complete Line of Sodium Hypochlorite Processing & Filtration Systems
Whatever your sodium hypochlorite production volume, Powell can provide a Sodium Hypochlorite Processing System to meet your unique needs.