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Working with Seawater

Electrochlorination Package Engineering For Seawater Systems Introduction

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Electrochlorination Overview

Index
Page 1) Introduction 2) Electrochlorination Demands a) b) c) d) Seawater Chlorine Demand Seawater Dosing Regimes Calculating the Chlorine demand Controlling the Chlorine Production 6 6 7 9 10 10 14 15 16 16 17 17 20 21 21 22 23 23 26 31 32 33 33 34 4

3) Process Chemistry a) b) c) d) e) Current Requirement (DC Amps) Electrolyser Anode Cathode Sizing Electrolyser Voltage Hydrogen Effect Power Requirements

4) Main Equipment Items a. b. c. d. e. f. g. h. i. Electrolysers Electrolyser Area Classification Electrolyser Installation Transformer Rectifiers Transformer Rectifier Installation Seawater Supply System Hydrogen Degassing Management Hypochlorite Dosing System Acid Cleaning System

5) Conclusion 6) Glossary 7) References Appendices 1) Typical Land Based Electrochlorination Package P&ID 2) Typical ECP turn down calculation

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Electrochlorination Overview

1) Introduction This information has been prepared on the basis of the authors practical experience in the supply of Electrochlorination Systems to a global market for the Power, Oil & Gas, Desalination and Offshore industries. Electrochlorination is essentially the electrolysis of a brine electrolyte, the electrolyte either seawater or an artificially produced brine solution. The chlorine related product of this electrolysis is sodium hypochlorite expressed as an equivalent in weight to chlorine. In the absence of known reference works the emphasis herein is provide a subject information level from which personnel of all disciplines can make an informed judgement regarding both identifying their electrochlorination requirements and assessment of a suppliers technical proposal. A basic electrochlorination demand calculator (excel) is available on the website as a free download which is hoped to be of assistance to readers. Chlorine is widely known for its properties for disinfection of potable water supplies and the control of marine fouling in seawater systems by virtue of being dosed at levels measured in ppm into those systems. It can be practically supplied in many forms and herein the main sources are identified with the emphasis retained on once through Electrochlorination. The basic electrochemical reaction is shown below where the electrolyte, a solution of sodium chloride in water, is subject to electrolysis by a DC electrical current.

NaCl + H2O

ELECTROLYSIS

NaOCl + H2

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Electrochlorination Overview

Amongst the many technical requirements for safe and efficient operation the engineering technology applied to electrochlorination systems has to address the following process criteria. a) The liquid media product is corrosive to most metallic materials and plastic is extensively used. b) The product is typically generated in low concentration solutions of <=2000mg/l carrier stream. c) The Electrochlorination package will generally permit only one variable product concentration with which typically multiple dosing points will be treated, the flow to each point modified to suit any change in the cumulative weight demand. d) The hydrogen by-product has to be safely managed. e) In the case of seawater systems process by-products include the formation of insoluble hydroxides and their appropriate management is essential to avoid precipitation within the piping systems and tanks. The main alternative sources of chlorine for water treatment are indicated below however it is assumed that the relative advantages and disadvantages of each system have been evaluated and electrochlorination has been selected. Liquid Chlorine Delivered to and stored on site, administered through evaporation and control equipment to the water system. Many installations that have demonstrated historical reliable operation have been replaced with Electrochlorination systems due to liquid chlorines hazardous nature. Bulk Sodium Hypochlorite. Delivered to and stored on site, administered through pumping systems and control equipment to the water system. Subject to rapid decay during storage at the concentrations logistics demand. Chlorine Dioxide Manufactured on site from a bulk chemical supply of Sodium Chlorite and Hydrochloric acid. An effective biocide however again subject to the logistics from which electrochlorination offers freedom.

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Electrochlorination Overview

2) Electrochlorination Demands a. Seawater Chlorine Demand Seawater Chlorine demand generally varies on a seasonal basis. Over an extensive preceding period the local seawater conditions and chlorine demand would have been monitored to determine the required Chlorine dosage required for the residence period of the seawater in the treated system. There will be environmental limits as to the free chlorine residual permissible to be discharged back to sea therefore the maximum chlorine seasonal demand plus the permissible residual will typically determine the maximum dosing regimes for a given system. With the dosing regimes determined and a known seawater process flow the maximum chlorine demand productivity can be calculated to a weight per unit time, typically kg/h. b. Seawater Dosing Regimes Dosing regimes typically comprise a combination of continuous and shock dosing of the seawater system. Continuous Dosing is a low level dosing regime that satisfies the chlorine demand of the treated seawater leaving a low level residual of free chlorine at the system outfall. Dependent on geographical location this can be anywhere between 1-5 mg/l with a residual of approximately 0.1 0.5 mg/l. Shock Dosing is at a frequency and duration determined by the seawater analysis wherein the level of hypochlorite dosing is periodically increased, typically 2 3 times the continuous dosing level. There are changing schools of thought as to the effectiveness and necessity of Shock Dosing however it has been understood to better control marine micro fouling, shock dosing for example for 20 minutes every 6 hours.. OEMs will typically propose suspension of continuous dosing during a shock dosing period however it could equally be cumulative, it is important that the consensus on this is agreed between client and OEM.

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Electrochlorination Overview

As will be shown in the later calculation examples the continuous dosing demand is by far the greatest factor in determining the product concentration required and as such, unless taken into account at the design stage, will determine that the shock dosing regime which will always be at a similar ratio to the continuous dosing, i.e. halve the continuous dosing regime and the shock dosing regime will inherently halve in a mass balanced electrochlorination system. Typically an electrochlorination package will vary its productivity by means of varying the DC current supplied to the Electrolysers, generally at a ratio of 10:1, this is explored further in 2d Note below as it there are other factors that can lead to confusion. Finally there is also KEMAs Technology of Pulse-Chlorination which is a relatively recent innovation which can be considered as high frequency low level shock dosing, e.g. 15 minutes on 15 minutes off with no other dosing regime involved. Where applicable it is considered environmentally and economically beneficial and is gaining in interest.

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Electrochlorination Overview

c. Calculating the Chlorine demand Given the dosing regimes have been determined for level, frequency and duration, with the seawater system flow rate known then the hypochlorite demand in each instance can then be calculated from the following simple formulae.

For each hypochlorite demand the following equation applies NaOCl kg/h = Alternatively NaOCl kg/h = Seawater Flowrate m3/h 1000 x ppm (NaOCl) x SG Seawater Flowrate m3/h 1000 x mg/l (NaOCl)

Note 1 mg/l = ppm x SG If mg/l and ppm are treated as equivalents then errors can occur in the weight calculations which on a marginally designed system could lead to failure to meet guarantee points during commissioning. As stated above it is an industry convention that, unless otherwise specified, continuous dosing will be suspended during shock dosing periods. Therefore the daily continuous demand will be for 24 hours minus the sum of the duration of the shock dosing periods, in the example utilised it is 2 hours hence the continuous dosing daily demand is calculated against the hourly demand for a period of 22 hours. Electrochlorination packages benefit from continuous operation and to achieve this mode of operation the media mass balance is averaged over a daily period. Therefore the sum of the daily shock dosing and continuous dosing demand is averaged over 24 hours to determine the required kg/h capacity of the ECP.

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Electrochlorination Overview

Example 1 Continuous Dosing Shock Dosing 20,000m3/h x 1mg/l = 20kg/h NaOCl 1000 20,000m3/h x 5mg/l = 100kg/h NaOCl 1000 4 Daily 15 minutes 1 h/day @ 100kg/h = 100kg/day 24-2 h/day = 22 x 20 = 440kg/day 540 kg/day 24 = 22.5kg/h

Shock Dosing Daily Frequency Shock Dosing Duration Shock Dosing Demand Continuous Dosing Demand ECP Capacity

A capacity specification would normally include a contingency to the productive capacity of the system for any potential increase in demand. Given a design product concentration for that maximum capacity and turn down by DC current variation this will result in the normal operating product concentration being at a lower level than the design value. Example 2 Required capacity Contingency Rated Capacity Product Concentration 22.5kg/h 10% 24.75kg/h = 100% 2000 mg/l

Electrolyser Seawater Carrier Stream Flowrate Flow m3/h = = NaOClkg/h x 1000 mg/l 24.75 x 1000 2000 = 12.375 m3/ h

For the actual demand at 22.5kg/h the product concentration will therefore be:mg/l = NaOClkg/h x 1000 Flow m3/h = 22.5 x 1000 = 1819mg/l 12.375

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Electrochlorination Overview

d. Controlling the Chlorine Production As stated above the chlorine production of an electrochlorination package is achieved by means of varying the DC current supplied to the electrolysers. The productive capacity is directly proportional to the DC current with a turn down ratio of 10:1, i.e. 10% - 100% output of an electrolyser stream. By this means the weight of hypochlorite produced varies, the mass balance remains constant, and the concentration of the product in the carrier stream varies. The DC current control therefore permits a variable weight to be produced in a stable mass balance. Mass balance through an ECP is required for three main reasons. i) ii) To maintain the designed electrolyte flow through the Electrolysers. It enables the continuous operation of the Electrolyser assemblies which is beneficial to their operation and longevity. (Anode coating loss is exacerbated by frequent energising and de-energising) Permits maintenance of the appropriate velocity through the dosing system pipe work that prevents precipitation of the insoluble hydroxide electrolysis by-products.

iii)

Important Note An ECP supplier will generally quote a turn down ratio of 10:1 for design productive capacity as stated above through varying the Transformer Rectifier DC current output. This strictly means that the concentration of NaOCl produced can be varied from 10% to 100%. The system mass balance however remains constant in most cases to maintain the required velocities in the dosing lines and retain all ancillary plant at its operating design conditions. An example of how confusion can arise is where, for example, when 10 main seawater pumps are to be dosed with NaOCl and the 10:1 turn down ratio is considered appropriate for running any combination of pumps from 1-10. This is not the case as the dosing diffusers for the individual pumps are unlikely to be able to accept the full mass balance of the ECP. Where this 10:1 ratio of process seawater pumps is required this must be considered at the onset of the project and appropriate design incorporated in the ECP control and distribution system. (See appendix 2 for a sample calculation)

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Electrochlorination Overview

3) Process Chemistry The primary equipment items for an Electrochlorination Package consist of seawater Electrolyser(s) and DC current supplies generally in the form of AC Transformers complete with Thyristor Rectifier assemblies.. Typically an electrolyser stream will be fed DC current from one transformer rectifier, with the electrolyser stream consisting of between 1 and 4 electrolysers. The electrolysers in one stream will be in hydraulic and electrical series wherein additional product weight is produced in each electrolyser which is progressively taken into solution within the stream seawater carrier stream to achieve the design hypochlorite concentration / weight at the electrolyser stream discharge. NaOCl kg/h = Seawater Flowrate m3/h 1000 x mg/l (NaOCl)

The electrolyser(s) stream will be selected for optimum capital equipment and consumable costs by the supplier and the following criteria apply in this process. Any number of electrolyser streams can operate in parallel. a) Current Requirement (DC Amps)

Central to the design of an ECP are the fundamentals of Electrochemistry as related to producing a given weight of Chlorine. To produce a given weight of Chlorine it is necessary to pass a quantity of DC electricity through a suitable electrolyte and the necessity is to calculate the power requirements and Electrolyser configuration to achieve that requirement. The calculation to determine the current required to pass through a single electrolytic cell when a potential difference (Voltage) is applied to the Anode and Cathode of that cell is as follows From Faradays laws of Electrolysis the Amperage required for the generation of a weight of Chlorine from a Sodium Chloride / Water solution would follow. m = AQ Where zF m = mass generated g A = relative atomic mass of Chlorine z = Charge number Cl- =1 F = the Faraday Constant = 96,500 C Q = quantity of electricity C (C= 1 Coulomb = 1A/second) Transposing the formula Q = mzf A

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Electrochlorination Overview

The data applicable to the process is shown in the following table Electrochemical Equivalent 1.3228 0.37605 Atomic Mass 35.4527 1.00794 Charge Number 1 1

Chlorine Hydrogen

Cl H

Therefore applying the calculation to determine the theoretical amperage requirement at 100% efficiency for 1 g of Chlorine Q=mzf A Q = 1 x 1 x 96500 35.4527 Q = 2721 C Therefore To produce 1g of Chlorine by electrolysis requires 2721 C(amp seconds) 3600 0.7558 A/h Similarly the electrochemical equivalent can be used. 1 0.7558 = 1.3228 The Amp hours that have been calculated above are for a single electrochemical cell to which a potential difference has been applied. Example 1 illustrates a capacity demand of 24.75kg/h which will be considered as being generated in a stream of 4 electrolysers. Therefore 24.75 4 = 6.19kg/h/Electrolyser Therefore for this example Amp/h = 0.7558 A/h x 1000 x 6.19 6.5kg Cl = 4678 Amp/h

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Electrochlorination Overview

This calculated value has to be subject to the Faraday efficiency attributable to the process, values can vary but are typically quoted in the range from 76% to 95% and are related to electrolyte composition and electrode materials. For this example 85% is chosen. Therefore for 10kg/Cl from a single electrolytic cell 6.19 kg Cl = 4678 Amp/h 0.85 6.19 kg Cl = 5504 Amp/h Parallel Plate Electrolysers typically consists of 10 Electrolysis Cells in electrical series, see illustrations below, therefore for 6.19 kg/Cl the amperage to be supplied to the Electrolyser stream would be 5504 10 = 550.4 A (DC) This would be the DC current supplied to the 4 x electrolysers in series to produce the weight determined in Example 1. NB A frequently asked question is whether the Sodium Hypochlorite produced by the electrolysis of a brine solution (Seawater) is a Chlorine equivalent. The forgoing calculation demonstrates that it is a direct equivalent.

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Electrochlorination Overview

ANODE

BIPOLAR INTERMEDIATE ELECTRODES

CATHODE

+ve

-ve

Parallel Plate 10 Cell Arrangement within an Electrolyser illustrating current pathways

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Electrochlorination Overview

Hypochlorite + Entrained Hydrogen

+ve

-ve

Laminar Electrolyte Fow over the open electrodes

-ve

+ve Axial Electrolyte Fow over the encapsulated electrodes Seawater

Typical and Alternative Parallel Plate Electrolyser Installation - Horizontal

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Electrochlorination Overview

b)

Electrolyser Anode / Cathode Sizing

Electrochlorination OEMs will choose an Anode coating most suitable and cost effective for the electrolyte salinity and temperature. Titanium will rapidly corrode in anodic conditions unless suitably coated, it is however suitable for cathodic operation uncoated. Anode coatings range from electroplated Platinum to MMO (Mixed metal oxides). Primarily Titanium will be used for anode substrate material with more commonly plain Titanium cathodes however possibly Hastelloy C cathodes. In the selection of the electrolyser the anode coating thickness will be determined by the DC current density for the design. The DC current density will be in the region of 1100A/m2 to 1500 A/m2 increasing to 2500 A/m2 in concentric tube technology electrolysers. For the worked example herein the anode area for each electrolyser cell based on 1500 A/m2 would be:550.4 1500 = 0.367m2/Cell (3.67 m2 / Electrolyser) Electrolyser Voltage Requirement The voltage (Potential Difference) necessary to drive the amperage required through the 10 Cells within the Electrolyser, and latterly through the electrolysers in series, is determined by a number of factors. The supplier needs to ensure that there is adequate voltage output from the transformer rectifier to ensure the DC current can pass through the seawater electrolyte in all seawater conditions. Therefore a complete seawater analysis, encompassing all seasonal and tidal variations of salinity and temperature ranges, should accompany an enquiry for an electrochlorination system Salinity of seawater can be expressed as either %, ppt (parts per thousand) , or more generally as Chloride level g/l. The usual representation of seawater is in ppt and this can be calculated from the Chloride level. S (ppt) = 1.80655 x Chlorides g/l Temperature also affects the resistivity of seawater and consequently the voltage requirement to ensure the required DC current can be passed through the electrolyser assemblies.

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Electrochlorination Overview

For a given anode coating there is a potential (Voltage) required before any current can be passed, no one figure can be quoted however 3 4VDC per cell would be reasonable to assume. Each OEM will have their own more complex methods of determining the voltage their system will require to comply with the seawater data specified and anode coating employed. For those interested there are calculations to determine the resistivity ratio of various seawater conditions that can be found in the Practical Salinity Scale.

Temperature Deg C Chloride g/l Salinity ppt

13 16.0 28.90

17.2 17.0 30.71

21.3 18.0 32.52

25.5 19.0 34.32

29.7 20.0 36.13

33.8 21.0 37.94

38 22.0 39.74

Figure 5 Typical data for determining electrolyte voltage requirement.

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Electrochlorination Overview

c)

Hydrogen Effect

Hydrogen evolved during electrolysis of a brine solution will be proportional to the weight of NaOCl being produced and progressively increasing as the electrolyte passes through the electrolysis cells. As the volume of hydrogen proportionally increases it has the effect of increasing the apparent electrical resistivity of the electrolyte, consequently requiring a higher than would otherwise be anticipated voltage to drive the DC current. To minimise the effect of the Hydrogen maintaining a pressure within the Electrolysers as close to the design operating pressure as is reasonable will minimise the effect. The higher the operating pressure the lower the volume of the Hydrogen in relation to the volume of the carrier stream, and subsequently a lesser impact on the resistivity. For large (e.g. >=50kg/h) electrolysers to operate efficiently in series the Hydrogen could be subject to hydrocyclone interstage degassing between electrolysers. This is removing the Hydrogen from the discharge of one Electrolyser before the carrier stream is introduced to the next Electrolyser in the series. This is necessary to minimise the voltage requirement by minimising the hydrogen effect on the electrolyte resistivity. d) Power Requirements

Having determined the voltage and amperage requirements for the required productive capacity the DC power requirement is then known. The simple result is :kWh
kWh/kg

=
=

Volts x Amps/h 1000

kWh Kg/h NaOCl

A supplier would be able to provide more comprehensive power consumption per kg/h taking ancillary plant consumption and efficiencies into account. The main variable between suppliers however will be reflected in the DC kWh/kg quoted.

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Electrochlorination Overview

4) Main Equipment Items a. Electrolysers The main operating design parameters for an electrolyser or electrolyser stream have been evaluated in the forgoing. The market consists primarily of the parallel plate electrolysers for larger installations and concentric tube technology for smaller systems. The factors that influence the selection are that the capital cost per kg is less for parallel plate systems and they can more easily generate higher concentrations of hypochlorite. This higher concentration means that the weight of hypochlorite for a given seawater carrier stream is greater, conversely the carrier stream for a given weight of hypochlorite is less, this consequently minimises the size of the distribution system in all respects. Parallel plate technology does however necessitate the provision of acid washing facilities for periodic removal of hydroxide deposits that naturally adhere to the cell cathodes. There are variations on a theme within the market including vertical or horizontal installations, similarly there are laminar and axial electrolyte flow paths within the electrolysers. Concentric Tube technology electrolysers are illustrated in Figure 6 below. The advantage of this system is that the electrolyte flow through the annular gap between the Anode and Cathode is of a turbulence and velocity that prevents the natural adhesion of the hydroxide by-products, essentially self cleaning and has no requirements for periodic acid washing. This is an advantage where the logistics of consumables and man power availability is difficult, primarily but not exclusively offshore. Again there are variations on a theme within the market, with vertical or horizontal installations, monopolar or bi-polar designs with wetted or non wetted inner electrode voids. In Figures 6 & 7 below are illustrated a vertical, monopolar and non wetted inner electrode variation of concentric tube technology.

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Electrochlorination Overview

Transformer / Rectifier -ve +ve Hypochlorite + Entrained Hydrogen

SeawaterInlet
Figure 6 Monopolar Tube Technology Electrolyser Schematic - Vertical
Monopolar Concentric Tube Electrolysis Hypochlorite + Entrained Hydrogen DC Current
Turbulent Flow in Annular Gap between Anode & Cathode Concentric Tubes

UPVC Liner

-ve CATHODE

-ve CATHODE

Hollow Centre Open to Atmosphere

Seawater

+ve ANODE

Seawater

Figure 7 Monopolar Concentric Tube Process Illustration.

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Electrochlorination Overview

Bipolar Concentric Tube Electrolysis

Plastic Coupling +ve Anode Outer Seawater -ve Cathode Outer

Centralising Spacers (Pips)

Inner Plastic Spacer

DC Current

Hypochlorite + Entrained Hydrogen Inlet Cone

Hollow Centre of Inner Bipolar Electrode Pressurised via equalisation holes

Seawater Inner Bipolar Electrode

Turbulent Flow in annular gap between inner and outer electrodes

Hypochlorite + Entrained Hydrogen

Figure 8 Bipolar Concentric Tube Process Illustration.- Horizontal

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Electrochlorination Overview

In all Electrolysers there is a necessity for the materials of construction to be both resistant to the corrosive media and also be of an electrical resistance to contain the process electrical currents and voltages. This necessitates the utilisation of some form of plastic material within the construction and associated piping. Dependant on the ambient and seawater temperatures of the location UPVC, CPVC or ABS will be utilised. These materials are subject to a temperature pressure relationship which will dictate the design pressure of the Electrolyser assembly. The supplier will have determined the applicable design pressure for the specified design temperature and will have provided appropriate protective devices to avoid over pressurisation. Experience has shown that this might not comply with general project specifications and sympathetic consideration of this inherent limitation should be exercised by specifying authorities as there will be little if anything that a supplier can redesign to accommodate a higher than technically necessary design pressure specification. b. Electrolyser Area Classification A seawater electrolyser stream is a hydraulic system and as such can be subject to media leakage. Any leakage will be infrequent and of short duration and dependent on the position of a leak within that stream a varying quantity of Hydrogen will then be released from entrainment in the leaked media. There are varying schools of thought within the industry regarding the hazardous area assessment relating to an electrolyser stream, varying from unclassified (safe) to Zone II. With an essentially multi flanged piping assembly it is however difficult to argue against Zone II C due to the potential for infrequent leakage of a hazardous gas (Hydrogen) for short periods in an electrolyser area. Typically a media leakage will have entrained Hydrogen of varying percentage content depending on the location of the leak within the Electrolyser Stream, however where interstage degassing is incorporated any leakage in the degas line will be of significantly higher percentage, <=100% H2. This suggests that the installation should be subject to a hazardous area assessment, e.g. to EN 60079-10, the extent of the hazardous zone defined and the installation designed, installed and inspected to comply with the applicable standard by a Notified Body or approved inspection agency, e.g. ATEX directive.

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The installation of a Hydrogen detection system above electrolyser streams is near universal. The usual argument for this device is to protect against some catastrophic failure that leads to a massive hydrogen release from the media, this is not a requirement for a hazardous area survey as these do not address catastrophic failures. It is of importance for those responsible for the preparation of equipment requisitions and specifications to satisfy themselves in this respect as there are different schools of thought amongst suppliers. It should be noted that EN 60079 is not a prerequisite standard for ATEX and is considered a conservative standard based on air changes per second. Therefore separate Electrolyser rooms are preferable to maintain ventilation and hazardous area limits to a reasonable level as Vz becomes a function of air changes per second. c. Electrolyser Installation This is an area where the materials of construction have an important impact. As stated previously there is a requirement for the use of plastic materials within the construction of an electrolyser assembly. The use of this material will have an impact upon the pressure temperature of the installation which has to be taken into account. The main considerations are whether the installation will be indoors or outdoors typically under a shade. Solar gain or freezing is not usually problematical for an outdoor installation in operation as the seawater flow is relatively massive compared to the Electrolyser mass and the process heat dissipation, solar gain or freezing ambient temperatures. It is conventional however to have part of the system idle due to a plant redundancy. In this instance solar gain and freezing are problematical unless the idle electrolysers are drained or alternative protection methods are employed, e.g. trace heating. d. Transformer Rectifiers The provision of a detailed seawater analysis and temperature range is critical for the correct specification of a Transformer Rectifier. The T/R output has to be for full current at the lowest and highest seawater conductivity conditions which implies that this has to occur over a range of output voltages. Any variation therefore from the specified seawater conditions could lead to an inability to meet guarantees points during commissioning and possible disputes between all parties over any extrapolation of the results.

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Electrochlorination Overview

e. Transformer Rectifier Installation i. Location Transformer Rectifiers can be of several specifications including combined, separate transformers and rectifiers assemblies, indoor or outdoor. Suppliers would not have a difficulty with any of these requirements either ONAN or ANAF. A problem however has been experienced when the installation is in a hazardous area. A supplier would by preference then supply a purge pressurised enclosure EEXp which does not always prove acceptable to project specifications. In the preparation of an enquiry or in the evaluation of a technical proposal it is advisable to avoid specifying explosion proof enclosures EExd. These are generally unavailable in the requisite sizes and do not readily lend themselves to dissipation of the heat generated in the transformer and rectifier assemblies.. With any rectifier installation there is the question of harmonic distortion to the supply utility. Experience has shown that this has not proven to be a significant problem and an agreement to install supply filters retrospectively should any problem occur in practice has been an argument satisfactory to most parties during bid clarifications. ii. Interconnecting Conductors Another consideration is the proximity of the Transformer Rectifiers to the Electrolysers. The DC output of the Transformer Rectifiers is of low voltage and high current and any voltage drop in the interconnecting conductors will reflect in the product DC kWh/kg. Typically a supplier would target approximately <=1 VDC loss between the T/R and the electrolyser to minimise the effect on the overall DC kWh/kg. In an installation where the T/R is remote to the electrolysers this would entail for example larger bus bars than ampacity or cable tables may suggest as suitable, increasing cost significantly. Therefore for example when a EExp T/R local to the electrolyser is unacceptable and a remote safe area T/R is installed the trade off on the interconnecting conductors has to be taken into the design and cost considerations.

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Electrochlorination Overview

f. Seawater Supply System Having established the importance of the seawater supply utility analysis lack of information regarding the pressures at which the supply utility will be provided will also be a design factor the Electrochlorination Package supplier. The mass balance through the ECP is generally dependent on a consistent stable seawater supply pressure which in most instances it is not possible to provide as a utility. Generally seawater utilities are bled from the high volume variable low pressure sources and as such will require seawater booster pumps to achieve the required operating pressure for the ECP. The ECP supplier will be faced with two difficulties in this area as the supply utility will also probably have been subject only to coarse screening. This is inadequate for electrolyser installations wherein flow paths will be narrow multiple channels necessitating prior screening to <1000m. Ideally automatic backwashing strainers will be utilised upstream of seawater booster pumps and pressure control equipment, should the minimum utility supply pressure be inadequate for this purpose then the strainers will be installed down stream of this equipment for which a change to the supply specification may not be ideal and the booster pumps up rated to accommodate the back flush volumetric requirement. g. Hydrogen Degassing Management Hydrogen is an inherent by-product of the electrolysis of seawater and has been previously discussed as creating a hazardous area when media leakage occurs in the electrolyser area. In normal operations this by-product is removed from the media to render the media suitable to be safely dosed back into seawater systems. The hydrogen can be disentrained from the media either by Hydrocyclone separation or more normally by permitting the media residence time in a degassing vessel. It is a proven industry convention that allowing a 5 minute residence time in a properly designed tank is adequate for the removal of hydrogen from seawater that has been subject to electrolysis. Experience has shown that enquiries occasionally specify greater residency periods; this is considered an unnecessary cost adder for that purpose in isolation. Degassing tanks can be either standalone with separate shock dosing media storage tanks or combined.

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Electrochlorination Overview

Degassing tanks can be provided as either naturally aspirated where the hydrogen is allowed to naturally disperse to atmosphere or in forced draught ventilated tanks where it is diluted with air on its escape from the surface of the media. Hydrogen has a Lower Explosion Limit of 4% in air and in the forced draught ventilation system typically sufficient air is provided to dilute the maximum possible hydrogen product to <1% Hydrogen in air such that when exhausted to atmosphere the mixture is non hazardous. Normally 2 x 100% air supply blowers would be provided and in some instances further redundancy is provided by service air or Nitrogen purging facilities. The implications of these choices are that with the naturally aspirated degassing tank the area around the tank top becomes Zone 0 C. In the case of the forced draught ventilation the area around the tank vent becomes Zone II C for a maximum of 5 minutes due to the possibility of power loss to the air supply blowers when no other redundancy is installed. Presuming the control system interlocks shut down the package when loss of dilution air is detected. This is a choice for those responsible for specifying an ECP enquiry and should be considered carefully. Where multiple, potentially redundant, naturally aspirated tanks are employed strict attention must be applied to work permit procedures in the event of maintenance activities Other points, or aide memoirs, would be to ensure that forced draught installations are protected against static by the use of earthed, electrically conductive duct materials. This should be part of a risk assessment or associated with an area classification or Hazop however there could be a possibility that neither of the latter could occur during completion of the project. If the dilution blowers are located in, and take suction from, an area that is previously classified as hazardous then it should be considered that the discharge of the degassing vent should be similarly classified. An alternative is to duct the blower suctions to an unclassified area. It has also been known for process engineers to consider any reactions between the released Hydrogen and whatever may constitute the prevailing hazardous media. Forced draught ventilation typically would include for filters and silencers to be specified for the blowers. This would be another advantage over naturally aspirated tanks where in desert conditions wind borne sand can enter the degassing tank which can be detrimental to the dosing system equipment.

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Typically, but not limited to, the choice of tanks will consist of UPVC lined GRP, GRP lined with Vinylester or GRVE. Each is satisfactory as resistant to NaOCl. Given that the forced draught ventilation system is at low pressure, typically 150-200mmwc, it is usual that both naturally aspirated and forced draught ventilation tanks are classified as atmospheric tanks. If tank level monitoring is by pressure ensure this 150mmwc is programmed into the control philosophy. Amongst the design criteria for a degassing tank it is important that the rate of fill and empty cycles is included in the specification when shock dosing is employed, BS 4994 is a common standard employed. For a rule of thumb the minimum flow rate for forced draught ventilation can be checked by the following calculation as suppliers could have contingencies built into their design :kg/h NaOCl x R x D x (Design Temp C + 273) = m3/h 273

kg/h NaOCl x 0.316 x 100 x (Design Temp + 273) = m3/h 273 24.75 Where kg/h NaOCl =ECP Maximum Hypochlorite production rate kilograms /hour (24.75kg/h from Example 2) R = 0.316 (the ratio of Hydrogen produced at 0C/kg/NaOCl) Design Temperature in C (40C used for this example) 273 = kelvin D is the dilution ratio of 100:1 m3/h = Volume of air required in cubic metres / hour x 0.316 x 100 x (40 + 273) 273 = 897m3/h

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Electrochlorination Overview

h. Hypochlorite Dosing System A typical dosing system consists of a degassing tank, pumps, and distribution system. As in the forgoing it is assumed that a comprehensive instrument and control package is employed to ensure correct and safe operation of the package. The degassing tank in this example is combined with a shock dosing storage requirement to illustrate the problems associated with correctly sizing the tank. It is at this point in the design of an ECP that the hydroxide by-product management must be addressed and an appreciation of the methods employed will be of assistance in evaluating a suppliers technical proposal. The hydroxides, Calcium Hydroxide and Magnesium Hydroxide, are insoluble in seawater and will precipitate into system blockages if not correctly managed. Similarly from this point in the system material selection has to address the corrosive nature of the hypochlorite media. On occasions, believed to be the result of biological bloom in seawater, electrolysis of seawater can result in the formation of bubbles when the hydrogen is disentrained in the degassing tank that will discharge from the tank vent if corrective measures are not available. The commonly used precaution is to install a seawater spray to the top of the tank of a suitable pattern to cause collapse of the bubbles within the tank. This impacts the mass balance of the system by dilution of the produced media and the mass flow rate of the spray has to be taken into account for dosing system sizing. This does not impact the weight of hypochlorite production.

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Electrochlorination Overview

i. Degassing / Shock Dosage Tank Sizing The initial criterion applied to the sizing of a degassing tank is to allow the 5 minutes residence time for the hydrogen by-product to disentrain from the media. In normal operations the flow rate from the electrolysers will be a consistent and continuous electrolyser discharge, i.e. tank infill. In simple terms this will be a volume of one twelfth of the flow rate. In a system that is designed simply for continuous dosing with no other requirements the degassing tank size will be slightly larger than this value to allow for alarm buffer volumes and ullage for hydrogen dilution. Given that there is a residence time control measures have to be introduced to ensure the insoluble hydroxides do not settle out. This should be emphasised in an enquiry and the means employed could include tangential inlet to the tank or tangential minimum flow lines returning from the dosing pumps, it could be an alternative to these methods to agitate the tank contents to ensure the hydroxides are maintained in suspension. Note if motorised agitators are considered the motors are likely to be in the classified area at the tank top and the media is corrosive. Should it be decided upon to allow the hydroxides to settle out and utilise a periodic discharge to drain there are factors that should be taken into account. One is to provide a flush to the drain line after the sludge discharge to avoid solidification of the hydroxides on exposure to air, another is to ensure that the mass loss during de-sludging is taken into account on the mass balance of the system. A conical base tank would be most suitable for this application. As illustrated above when shock dosing is employed, unless specified otherwise, a supplier will normally presume that continuous dosing is suspended during the shock dosing period(s). In this system the shock dosage volume / weight is accrued by a rate of gain on tank volume in the continuous dosing interval, i.e. the continuous dosing flow rate extracted from the tank is less than the tank infill flow rate from the electrolyser(s). The storage volume required will however be less than the shock dosage volume, the storage volume will be the shock dosage volume minus the inflow volume during the shock dosing period and it is this volume that will be added to the residence volume to largely determine the size of the tank. Again suitable buffer volumes will be added to avoid spurious level alarms due to minor variations in level and flow control. This has been a subject of confusion however in the case of a single dosing point application the calculations are relatively simple. When a dosing system is employed to treat multiple injection points of varying dosing requirements, from a single tank, then the calculations to determine the optimum tank size become more complicated.

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Electrochlorination Overview

To illustrate this charts below example a system where the tank sizing has to accommodate 6 points of application and the daily timings of the shock dosing frequencies have been distributed to optimise on the tank size.
Dosing Timings
0.90

0.80

0.70 1 CD 2 CD 0.60 3 CD 4 CD m3/min 0.50 5 CD 6 CD 1 SD 0.40 2 SD 3 SD 0.30 4 SD 5 SD 6 SD 0.20

0.10

0.00 1 55 109 163 217 271 325 379 433 487 541 595 649 703 757 811 865 919 973 1027 1081 1135 1189 1243 1297 1351 1405 1440mins = 24h

Total Tank(s) Level Fluctuation

40.00

35.00

30.00

25.00

m3

20.00

Tank Level

15.00

10.00

5.00

0.00 0 42 84 126 168 210 252 294 336 378 420 462 504 546 588 630 672 714 756 798 840 882 924 966 1008 1050 1092 1134 1176 1218 1260 1302 1344 1386 1428

1440mins - 24h

A supplier should be required to demonstrate that this key element of the package design has been evaluated to confirm that the mass balance and tank size rationalise.

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Electrochlorination Overview

ii. Hypochlorite Distribution Piping and pumping installations are commonly understood disciplines and the design constraints applicable to electrochlorination systems are few but essential to address. Of the metallic materials available for piping only Titanium is considered suitable and naturally resistant to NaOCl. This would usually represent a prohibitive cost, for example on some installations the dosing lines are >5km in length. Other materials would include the plastics referenced above, RLCS (Rubber lined carbon steel), HDPE (High Density Polyethylene) or GRVE (Glass reinforced vinyl ester). The latter should not be confused with GRP (Glass reinforced polyester) as this material is not resistant to NaOCl. Other than for skid mounted packages it is generally more cost efficient to utilise a piping system that lends itself to complete fabrication on site. When, for example, RLCS is selected consequentially drawings (ISOs) require significantly more attention to detail. Similarly the supply schedule will be extended if field joints are to be returned for factory completion. In most instances the appropriate plastic lines for the location will be quoted to present the most economical technical proposal unless an alternative is specified. Pump material selection is limited; Titanium and Hastelloy C have been used successfully with experience suggesting the former for consistent reliable corrosion resistance. There are also ranges of FRP pumps available that are also suitable for the media. To accommodate the potential for sand or other wind borne material contamination of the hypochlorite solution consideration should be given to SiC/SiC mechanical seal faces on centrifugal pumps. The hydroxide content of the media has proven not to be abrasive or detrimental to these seal faces. It is however the hydroxide content and the necessity to avoid its precipitation that dictates dosing line velocities are generally maintained between 0.75m/sec and 3 m/sec. This applies equally to pumped and gravity feed systems. Gravity feed is used successfully where the head of the tank is adequate to maintain the required media velocity for a given length and size of piping, it should however be considered that for gravity feeding of a stored shock dose volume that the head will decrease as the tank level falls and the minimum head should be used for those calculations.

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Electrochlorination Overview

A gravity feed system should also include a weir arrangement and syphon breaker to ensure that the level in the tank does not go below the Low Low level set point as this would otherwise drain media that has not been fully detrained of hydrogen into the dosing system. Low Low set point is usually being at the level for the volume required for 5 minutes media residence in the degassing tank, which typically is a greater volume than would be used for pump loss of suction protection. Should there be a need to continuous dose and shock dose down the same line the velocity constraints and losses should be qualified as acceptable for both dosing flow rates. This can be achieved by appropriate line sizing or an iterative process of evaluation by adjusting the product concentration. It may not be possible to achieve the velocity constraints for both dosing regimes through a single line then separate lines should be considered for confident operation without blockages from precipitated hydroxides. An area where this is sometimes overlooked is when continuous and shock dosing pump suctions are instinctively designed with a single header to the degassing tank. Here the NPSHr for the pumps will necessitate a low velocity of 0.75-1m/sec to avoid potential cavitation and precipitation. Where the flow rate of each dosing regime will be significantly different prior evaluation of this criterion will give early indication of whether single or separate suction headers are required. This equally applies where speed control is exercised over pumps rated for the dual capacity of continuous and shock dosing regimes, if recirculation is applied the problem is not the same. Ball valves have proven successful for seawater duty however they are not recommended to be utilised for seawater generated hypochlorite solution, where these valves are not regularly exercised the hydroxides can collect and cause difficulty in operation. Diaphragm and Butterfly valves are the better solution for this media. Flow control valves of the rotating plug or characterised port ball valves have proven successful due to their continuous modulation and the relatively high flow rate through the valves keeping the valve free of hydroxide accumulations. What may not be obvious to all readers is that the daily demand for hypochlorite has been averaged and the ECP product will be at a consistent concentration of hypochlorite. Therefore at the same concentration to deliver a greater weight over time dosage of hypochlorite to a seawater system the flowrate of the hypochlorite has to be increased. During a bid evaluation it may be considered that a consistent dosing flowrate of variable product concentration would be preferable. Whilst this is possible it does mean that the ECP will have to be of significantly larger generating capacity than when the demand is averaged to accommodate the maximum instantaneous hypochlorite demand.

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Electrochlorination Overview

i. Acid Wash System During the electrolysis of seawater the hydroxide by-products naturally adhere to the cathodes unless prevented by the employment of specific design parameters. It should be unnecessary for concentric tube technology electrolysers but will be a periodic requirement for parallel plate technology electrolysers. Hydroxide contamination of the cathodes will, over a period of time, be detrimental to the efficiency of the electrolysis eventually causing high voltage requirements and in the final stages reduce electrolyte flow. The process of acid washing includes recirculation of a 5-7% HCl solution through an electrolyser stream to dissolve the hydroxides therein. It is difficult to predict the frequency at which acid washing will be required depending much on seawater quality and mode of operation. Typically acid washing would be required once every 2-4 weeks for a period of approximately 2-4 hours. Given the frequency of operation it is usually provided as a manual system although a degree of automation can be provided. The sizing of the acid wash system will vary according to the size of the ECP installation due to the differing volumetric requirements. The acid storage tank at a minimum has to be capable of filling both the electrolyser stream and the associated acid delivery pipe work. It should also be considered that the larger the acid wash tank volume the less frequent will be the requirement for strengthening and / or neutralising and disposing of the spent acid. It is preferable within the system design to provide for evacuation of the acid from the electrolyser stream back to the acid wash tank on completion of a wash cycle. This can be achieved by the provision of an eductor system driven by means of the acid wash pump or through gravity if respective elevations of the equipment permit. In areas where there is a high Manganese content in the seawater there could be a requirement to introduce a periodic acid wash of a hydrogen peroxide mixture to remove Manganese Dioxide electrolysis by-product which can coat the electrodes and similarly adversely impact their efficiency. Alternatively it has been reported that Electrolysers with Hastelloy C cathodes can be cleaned by brief periods of reversed polarity operation, this is not possible with Titanium cathodes.

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Electrochlorination Overview

5) Conclusions The forgoing addresses the potential inexperience of a specialised technology in personnel charged with the preparation of equipment specifications and assessment of suppliers technical proposals. System or equipment redundancy has not been addressed as this will be dependent on client and supplier agreement. The only certainty is that an electrolyser stream that requires acid washing will be off line and necessitate reduced rates of dosing for a period of time if redundancy is not incorporated in the generating capacity. Similarly it is anticipated that the requisite Hazardous Area Assessments, Risk Assessments and Hazop will be conducted for any given project. ISPC does offer a consultancy that is intended to set the design foundations for a project to improve the efficiency of its execution to a successful, cost effective, conclusion. If you have read this far, thank you, ISPC hope the forgoing has both been of interest and of benefit. We do however have to include the obligatory disclaimer that the information herein is of a general nature and ISPC cannot assume any responsibility for inaccuracies or omissions nor for any utilisation of the content for any purposes by others.

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Electrochlorination Overview

Glossary A/m2 ABS ANAF CD CPVC DC ECP EExd EExp Electrolyte FRP g/l GRP GRVE HCl HDPE kg/h Low Low m/sec m3/h Media mg/l MMO mmwc NaCl NaOCl ONAN ppm ppt P&ID RLCS SD SG SiC T/R UPVC m 6) References TBA. Amps per square metre Acrylonitrile Butadiene Styrene Air natural air forced (Cooling) Continuous NaOCl dosing Post-chlorinated Polyvinyl Chloride Direct current Electrochlorination Package Explosion Proof protection Purged Pressurised enclosure protection = Media Fibre reinforced plastic grams per litre Glass reinforced polyester Glass reinforced polyester Hydrochloric acid High Density Polyethylene Kilogram per hour Indicates a low measured variable trip set point Metre per second Cubic metres per hour Seawater and Sodium Hypochlorite Solution milligram per litre Mixed Metal Oxides anode coating millimetre water column Sodium Chloride Sodium Hypochlorite (also referenced as hypochlorite) Oil natural air natural (Cooling) Parts per million Parts per thousand, Piping and Instrument Diagram Rubber lined carbon steel Shock NaOCl dosing Specific Gravity Silicon carbide Transformer Rectifier Unplasticised Polyvinyl Chloride micro metre

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Electrochlorination Overview

APPENDIX 1 Typical Electrochlorination Package P&ID

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Electrochlorination Overview

TRANSFORMER RECTIFIER 1

TRANSFORMER RECTIFIER 2

TRANSFORMER RECTIFIER 3

AC -ve

DC +ve

AC -ve

DC +ve

AC -ve

DC +ve

SEAWATER ANTIFOAM

H2 DETECTOR RO TIT DPIT M RO FCV TIT

H2 DETECTOR

H2 DETECTOR
SEAWATER + NaOCl

TIT

PIT

FCV

FCV

ELECTROLYSER 1D

ELECTROLYSER 2D

ELECTROLYSER 3D

ELECTROLYSER 1C

ELECTROLYSER 2C

ELECTROLYSER 3C

ELECTROLYSER 1B

ELECTROLYSER 2B

ELECTROLYSER 3B

SEAWATER UTILITY

ELECTROLYSER 1A
DPIT

ELECTROLYSER 2A

ELECTROLYSER 3A

PIT M

FIT

FIT

PI

TIT

SAMPLE / VENT

SAMPLE / VENT

FIT

SAMPLE / VENT

SEAWATER STRAINERS 2 x 100% SEAWATER BOOSTER PUMPS 2 x 100%

ACID WASH RETURN

ACID WASH SUPPLY

SD SEAWATER FLUSH

NOTES: 1) INDIVIDUAL ELECTROLYSERS MONITORED FOR VOLT BALANCE. OMMITTED FOR CLARITY 2) ELECTROLYSER DISCHARGE FCV SHOWN AS MANUAL WITH AUTOMATIC OPERATION OPTIONAL. 3) HYDROGEN DETECTORS MOUNTED ABOVE EACH ELECTROLYSER STREAM. 4) ELECTROLYSER BYPASS LINE SHOWN. PROVIDED TO MAINTAIN MASS BALANCE WHEN NaOCl DEMAND REQUIRES ONLY ONE STREAM IN OPERATION.

ELECTROLYSER STREAMS 3 x 50% 5) DENOTES MEDIA WETTED EARTHING RING FOR PROCESS DC CURRENT CONTAINMENT. 6) STRAINERS SHOWN DOWNSTREAM OF BOOSTER PUMPS, CAN BE UPSTREAM IF MINIMUM SEAWATER UTILITY PRESSURE ADEQUATE. 7) SEAWATER FLUSH TO SHOCK DOSING PUMPS OPTIONAL. TAKEN FROM UTILITY TO MINIMISE BOOSTER PUMP AND STRAINER SPECIFICATION

TYPICAL LAND BASED ELECTROCHLORINATION PACKAGE P&ID SHEET 1 0F 3

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Working with Seawater

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Electrochlorination Overview

ISPC Consultancy

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Electrochlorination Overview

ACID WASH RETURN

POTABLE WATER

PH

ACID WASH SUPPLY

FI

PI VENT & SEAL POT

FS

PI ACID WASH TANK

SAFETY SHOWER ACID WASH PUMPS 2 x 100%

LIT HCl O'FLOW & SEAL POT NaOH

BUND

NOTES: 1) PH MONITORING IS BY MEANS OF A CONDUCTIVITY METER

TYPICAL LAND BASED ELECTROCHLORINATION PACKAGE P&ID SHEET 3 0F 3

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Working with Seawater

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Electrochlorination Overview

APPENDIX 2 Typical Electrochlorination Turn Down Analysis

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Electrochlorination Overview

Hypochlorite Dosing System Analysis Hypothetical Case Study Assuming mass balance infill to the Degassing Tanks for Continuous Dosing and Shock Dosing has been addressed Dosing Regimes CD 2 mg/l SD 5 mg/l Frequency and Duration not applicable to Piping ECP Production Points of Application Seawater Supply Pumps Pump A Pump B SSP 6 2 22 2 ADC Max h/day h/day SG 1.025

30 1800

mins mg/l

4 T/R

Day 1500

qty qty m

5+1 1+1

Duty Duty

5000 2000

m3/h m3/h

ECP Dosing to Points Of Application Distance 1500 Supply Pump Permutations of operation weight requirement Pump A Pump A Pump A Pump A Pump A Pump A Pump B Pump B Total CD Demand @ CD NaOCl Flowrate SD Demand @ SD NaOCl Flowrate

1xA 5000

1xB

1A+1B 5000

2A+1B 5000 5000

3A+1B 5000 5000 5000

4A+1B 5000 5000 5000 5000

5A+1B 5000 5000 5000 5000 5000 2000 27000 54 30.00 135 75.00

2000 5000 10 5.56 25 13.89 2000 4 2.22 10 5.56

2000 7000 14 7.78 35 19.44

2000 12000 24 13.33 60 33.33

2000 17000 34 18.89 85 47.22

2000 22000 44 24.44 110 61.11

m3/h m3/h m3/h m3/h m3/h m3/h m3/h m3/h m3/h kg/h NaOCl m3/h @ kg/h NaOCl m3/h @

1800 1800

mg/l mg/l

Therefore Electrochlorination Package Duty Maximum CD Demand 54 kg/h NaOCl Maximum SD Demand 135 kg/h NaOCl Daily Averaged demand 60.75 kg/h NaOCl Design NaOCl concentration 1800 mg/l Media Flow rate 33.75 m3/h (Tank Infill)

ECP Configuration

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Electrochlorination Overview

ECP Streams T/R's Hypochlorite Dosing Pumps CD NaOCl Max Flowrate SD NaOCl Max Flowrate

3 3

@ @

50% duty 50% duty

2 2

duty duty

@ @

16.88 m3/h 10% to

100% Stream Duty

30.00 75.00

m3/h m3/h

Supply Pump Permutations of operation % requirement Pump A Pump A Pump A Pump A Pump A Pump A Pump B Pump B Total CD Demand @ SD Demand @ Average Demand on ECP ECP % Output 1xA 5000 1xB 1A+1B 5000 2A+1B 5000 5000 3A+1B 5000 5000 5000 4A+1B 5000 5000 5000 5000 m3/h m3/h m3/h m3/h m3/h m3/h 2000 m3/h m3/h 27000 m3/h 54 kg/h NaOCl 135 kg/h NaOCl 60.75 kg/h NaOCl 100.0% 2 x Streams 100.0% 1500 1800 30.00 75.00 6 5.00 12.50 5A+1B 5000 5000 5000 5000 5000

2000 5000 10 25 11.25 18.5% 2000 4 10 4.5 7.4%

2000 7000 14 35 15.75 25.9% 25.9% 389 467 30.00 75.00 2 15.00 37.50 51.9% 778 933 15.00 37.50 7.50 18.75

2000 12000 24 60 27 44.4% 44.4% 667 800 30.00 75.00 3 10.00 25.00 88.9% 1333 1600 15.00 37.50 5.00 12.50

2000 17000 34 85 38.25 63.0% 63.0% 944 1133 30.00 75.00 4 7.50 18.75

2000 22000 44 110 49.5 81.5% 81.5% 1222 1467 30.00 75.00 5 6.00 15.00

Options of 1 or 2 Streams to meet various demands T/R Output 2 x Stream 18.5% 7.4% T/R Amps 278 111 ECP Concentration 333 133 Actual Dosing Flowrate CD 30.00 30.00 SD 75.00 75.00 Diffusers in operation 1 1 Flowrate Per Diffuser CD 30.00 30.00 SD 75.00 75.00 T/R Output 1 x Stream T/R Amps ECP Concentration Actual Dosing Flowrate Flowrate Per Diffuser 37.0% 556 667 15.00 37.50 15.00 37.50 14.8% 222 267 15.00 37.50 15.00 37.50

ADC mg/l m3/h m3/h m3/h m3/h

33.75 m3/h

CD SD CD SD

ADC mg/l m3/h m3/h m3/h m3/h

16.88

m3/h

Tank Infill

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Electrochlorination Overview

Dosing Distribution Line Sizing Assuming separate single headers for CD and SD Continuous Dosing Velocity Maximum Velocity Minimum 3 m/sec 30.00 m3/h 1.5 15.00 m3/h Shock Dosing Velocity Maximum Velocity Minimum 3 m/sec 75.00 m3/h 1.5 37.50 m3/h

59.47 59.47

mm ID mm ID

94.03 94.03

mm ID mm ID

Conclusion : Header Sizing can be engineered to available line sizes Point of Application Diffuser Sizing Continuous Dosing Velocity Maximum Velocity Minimum 5 m/sec 30.00 m3/h 1 5.00 m3/h Shock Dosing Velocity Maximum Velocity Minimum 6 m/sec 75.00 m3/h 1 12.50 m3/h

46.06 42.05

mm ID mm ID

66.49 66.49

mm ID mm ID

Conclusion: Careful analysis of line diffuser losses required for dosing pump sizing due to 6:1 potential ratio in media velocities.

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Electrochlorination Overview