Sodium Hypochlorite High Strength Low Salt Production System

Our Sodium Hypochlorite High Strength Low Salt Production System (HSLS Hypo System) is a continuous system designed to safely produce sodium hypochlorite up to 30 wt.% sodium hypochlorite and only 8.5 wt.% salt. With the reduction in salt content and with reduced levels of sodium chlorate and sodium perchlorates achieved using the patented technology, diluted High Strength Low Salt Hypo is a high-quality product that is more stable, has a significantly extended shelf life, and is 4% lighter in weight in comparison to standard sodium hypochlorite (13 wt.% containing 10.4 wt.% salt).

The sodium hypochlorite high strength low salt production process is a unique two stage process consisting of the chlorination stage and the salt removal stage. The plant is completely automatic and requires only that someone be available if a process upset occurs. The system has an adjustable production rate and can produce strengths up to 385 grams per liter available chlorine. Systems are completely skid mounted on structural steel frames. The dimensions for a system that could convert 25 STPD of chlorine to 30 wt.% hypo would be approximately 40′ long x 40′ wide x 20′ high.

The HSLS Hypo System offers many unique production, distribution, and storage advantages, never before available:

Up to 35% of the salt used to make the chlorine and caustic is reclaimed by the system. For example, a plant using 100 short tons of chlorine per day could expect to recapture approximately 60 short tons per day (21,000 short tons per year) of salt. The reclaimed salt can be recycled back to the brine treatment system of the plant. This benefit can generate a significant reduction in raw material costs since less salt will need to be purchased to operate the plant.

When diluted to 13 wt.%, HSLS has a salt content of only 3.7 wt.%. Due to the lower ionic strength of the solution, diluted HSLS has a significantly reduced rate of decomposition. The HSLS has a half life that is almost twice that of standard sodium hypochlorite.

30 wt.% HSLS can be shipped up to 400 miles compared to the typical 150-200 mile shipping range of standard sodium hypochlorite. Transportation costs are significantly reduced in that more highly concentrated product can be shipped to twice the shipping range, allowing the distributor to increase their customer base while also lowering their shipping costs. A 5,000 gallon shipment of 30 wt.% HSLS equals 13,750 gallons of 13 wt. % of standard sodium hypochlorite.

Because it is lighter and more stable than standard sodium hypochlorite, shipping diluted HSLS offers many cost saving advantages. Unlike shipments of standard sodium hypochlorite, decomposition of the product is minimized to an insignificant rate. As a result, the diluted HSLS arrives at its destination close to the same strength as when it was originally shipped.

HSLS diluted to 13.5 wt.% has the same shelf life as standard 10.5 wt.% sodium hypochlorite. Companies shipping 13.5 wt.% sodium hypochlorite can increase their shipment load (on a 100% basis) up to 33% without any increase in decomposition.

One 5,000 gallon shipment of 13 wt.% diluted HSLS contains 3,900 pounds less salt than standard sodium hypochlorite.

Before now, many products in the consumer market were limited due to the higher salt content found in standard sodium hypochlorite. HSLS increases the possibilities of offering better and more cost-effective formulations of specialized household cleaners to the consumer, resulting in an improved product.

Our systems are built for a capacity specific to customer requirements. Typically, HSLS systems are rated to consume anywhere between 1 – 9 short tons of chlorine per hour. Contact us if your project requires a higher or lower flow rate.

The systems are accurate and will meet allowable variations between system set points and final product strength. Accuracy is dependent on the flow measurement device, but a typical system would have an accuracy of ±0.15% weight percent for the final product.

Our systems are engineered to have a repeatable final product strength. You can expect it to have repeatability with less than 1% variance.

Typically has a turndown ratio of 4:1, which is the ratio of the design capacity to the minimum rated capacity.

We provide process equipment and instrumentation based on the required performance and price points of the customer and can use a variety of manufacturers to meet existing plant specifications. The systems are shipped fully assembled and programmed after being electrically and hydrostatically tested.

We utilize industrial PLC control systems such as Allen Bradley and Siemens. Control systems are installed in weatherproof enclosures and typically affixed to the process system frame if not remote mounted. A touch screen HMI (Human Machine Interface) is typically included so that the operator can easily view all critical process data. This information can easily be networked to other Powell equipment, an existing DCS (Distributed Control System), or other control systems using several common protocols. It utilizes VPN devices which provide us with a secure, remote connection to the system, and allows us to provide programming updates and assist in troubleshooting, when necessary. A comprehensive Operation & Maintenance Manual is provided with every system and includes complete electrical prints and programming logic. We can provide UL listed or CE marked control panels and meet a variety of electrical classifications.

Each project undergoes an engineering review to ensure the materials of construction are appropriate for the project specific process conditions. Each reactant stream may have different materials of construction. Testing, X-ray services, and pipe welding to meet international and domestic standards such as ASME B31.3 are also available. Process piping connections are typically 150# ANSI flanged, and standard skid components are as follows:

• Frame – Welded carbon steel equipment frame for skid-mounting of system components. Each frame comes with mounting feet and bolt holes for anchoring.
• Fasteners – Fasteners are available in a variety of materials and process piping gaskets are typically expanded PTFE.
• Electrical Conduit – Electrical conduits are typically PVC, galvanized, or PVC coated rigid steel. Modular cabling with multi-pin connectors can also be provided in place of conduit.
• Instrument Air Header – A galvanized instrument air manifold is provided when required. This includes a filter, pressure regulator, solenoid valves, and individual locking isolation valves.

We can provide a variety of tie point locations, flow directions, and frame configurations to meet project specific constraints. Our systems are modular in nature and skid dimensions take into consideration the need for transport via truck or shipping container.

Liquid chlorine at a minimum of 120 PSIG (8 bar) or vapor chlorine at a minimum pressure of 3 PSIG (0.2 bar).

Concentrated sodium hydroxide solution at a pressure of 45 PSIG (3 bar).

Softened water at 45 PSIG (3 bar).

At 45-80 PSIG (3 bar) if dissolving salt is required.

An uninterrupted source of single-phase power is required for the control system. A UPS (Uninterruptible Power Supply) can be provided if necessary. A source of three-phase power is also required for all motors.

A source of clean, dry, oil-free instrument air at a minimum of 80 PSIG (5.5 bar).

A maximum of 85°F/18°C.

We assist you by providing a variety of upstream and downstream equipment, instrumentation, automation, motor starters, and drives, as required by the client. Functions such as tank truck loading, bottling operations, tank farm management, including integration with existing controls, networks, and distributed control systems lead to greater safety, increased efficiency, and improved productivity. We also provide a properly engineered cooling water system, complete with cooling tower, cooling water pump, and a “chemical-free” method of treating the cooling water.

Our systems are supported by our experienced technicians who can provide startup, operator training or perform scheduled preventive maintenance and calibration. Additional charges apply for these services.