Chlorine Generator
Process
The i-chlor chlorine generator is as
simple as a battery with no moving parts. This
page is intended to help you understand the simplicity of the
i-chlor chlorine
generator leaving you thinking... why hasn't anyone thought of this
before!
On this page you will discover:
To view a video demonstration on the chlorine
generation process, please click here! This may take a few
minutes, so please be patient.
Process
Components
The i-chlor chlorine
generator requires a cell, DC power supply (battery
charger, battery, solar power), energy source (power outlet,
generator), a pressurized water supply to operate the venturi
ejector, and a vacuum relief reservoir to prevent collapse of
the salt reservoir. Please note that the use of a
union pipe fitting in the cell configuration as well as the
i-chlor chlorine generator system are
patented.
Purchase of systems and/or components from Chlorine
Generators, Inc. will not be considered patent
infringement.
Cell: The cell includes the
anode and cathode compartments that are hydraulically isolated
by an ion selective membrane located between the two cell
compartments. The anode compartment contains the
anode (electrode), saltwater electrolyte, and
chlorine. The cathode compartment contains
the cathode (electrode), sodium hydroxide (caustic soda)
electrolyte, and hydrogen. The hydrogen produced from
the cathode compartment is vented to the outside
atmosphere. The two cell compartments are joined
together by a union pipe fitting that also holds the ion
selective membrane between the union flanges.
Salt Reservoir: The
anode compartment of the cell is connected to the salt
reservoir. The salt reservoir contains the salt,
saltwater, and chlorine. Chlorine gas generated from the
anode compartment bubbles up into the salt reservoir which is
swept under vacuum by the venturi ejector into the water
supply.
DC Power Supply: The DC
power supply can be any DC battery charger of adequate size to
handle the needed chlorine demand. Our i-chlor system utilizes a power supply
having an adjustable amperage setting that once set, maintains
a constant amperage output regardless of temperature,
conductivity, and resistance changes. This means a
constant chlorine output, even at very small chlorine dosage
levels.
Energy Source: The
energy source is basically the 120 VAC power outlet
supply.
Pressurized Water
Supply: The water passes through a venturi
creating a vacuum that is applied to the salt
reservoir. The discharge from the vacuum
ejectors is highly chlorinated water in the form of
hypochlorous acid and/or hypochlorite ion.
Vacuum Relief
Reservoir: Water or sodium hydroxide is added to
the vacuum relief reservoir which allows excess atmospheric
air to be added to the venturi vacuum system preventing
collapse of the salt reservoir.
Process
Installation
Provided the plumbing for the system is
complete (existing vacuum ejector, or simply using a garden
hose connected to the ejector) It should not take longer than
30 minutes to an hour to have your chlorine generator
completely operational. The installation
includes the following steps:
- remove components from the box, check
contents for any missing or broken parts
- soak the membrane in warm water
- install the membrane on the cell flange
- connect tubing between the cell and the
salt reservoir
- fill vacuum relief reservoir with
water
- add salt and water to the salt reservoir
- add water and dry sodium hydroxide to
the cathode compartment
- connect water supply to venturi ejector
- connect the vacuum tubing from the anode
compartment to the venturi ejector
- plug electrode connector into the power
supply connector
- turn on power supply switch
- plug power supply into power circuit
- operate venturi ejector and energize power
circuit, adjust power supply to desired chlorine
level.
System
Operation
The system operation includes the control of
the system, addition of salt and water to the salt reservoir,
periodic dilution of the sodium hydroxide in the cathode
compartment, and occasional cleaning of the cell
membrane.
There are several ways the chlorine generator
can be operated. The simplest way is to plug the power
controller into a power outlet that is only energized at times
when the generator is needed for chlorine
production. This on/off operation procedure can be
accomplished by installing a power control relay on the power
outlet circuit. Nearly all municipal well
installations include this type of circuit typically used for
a hypochlorination pump. A PLC programmable controller
(PLC) can also be used to energize the circuit
when needed.
The power supply has a constant amperage
feature that allows precise chlorine dosage control regardless
of brine temperature, membrane resistance, or solution ionic
strength.
At a booster pump station having multiple
pumps, a chlorine generator for each pump circuit will supply
the step chlorine dosage needed depending on the number of
pumps operating. This operational procedure eliminates
the need for an electronic logic controlled loop and/or
pacing valve systems.
The chlorine generator's
small size and portability allows the operator to use the
chlorine generator practically anywhere with multiple seasonal
uses. In the northern cold regions, use the chlorine
generator to fill you laundry tub when you are not needing the
system on your frozen swimming pool.
Dose Control
Chlorine
output is adjusted by the power input of the process. Every 15 amperes of
direct current (DC) provide a chlorine production rate of 1
pound per day (24 hours). The graph below
illustrates the equivalent chlorine production at the desired
amperage setting.
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Note: With time, the membrane accumulates
calcium and other mineral deposits that increase the
resistance between the electrodes. The increased
resistance causes the power supply voltage to increase
to maintain the desired amperage output. When
the high end voltage is reached, a reduced amperage
output and a corresponding reduced chlorine output
will also be observed. The system needs periodic
membrane cleaning to recover the desired amperage
output. A water softener system can be added to
the system water supply to reduce the amount of
calcium, thus increasing the service life of the
membrane.
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The power supply
includes both constant voltage and constant current (amperage)
adjustments. Since dosage is a direct relationship with
amperage, the power supply's constant current setting is
desired in most applications. To set the power supply at
constant current, the voltage adjustment potentiometer is set
to its full on level (10 turns clockwise).
Adjustment of the amperage potentiometer
will then increase or decrease the amperage output
to the desired current setting, and maintain that current
setting regardless of any voltage changes in the
process. For example, a chlorine output of 0.5 lbs
per day is desired for a 100 gpm well. Based on amperage
conversions, approximately 8 amperes of DC power is
needed for the well.
The operator would adjust the voltage control dial full
on allowing for the power supply to operated on constant
current, then adjust the current dial to achieve a power
output of 8 DC amperes for the
cell.
Salt
Addition
For every 50 lb bag of water softener
salt, approximately 30 lbs of chlorine is made.
The frequency of salt addition depends on the operating
cycle. For example:
A 150 gpm
municipal well operating a total of 6 hours per day (54,000
gpd) using a 1.5 lb/day (22 amperes) chlorine dosage
rate (0.5 mg/l chlorine residual w/ a 0.35 mg/l chlorine
demand) will need to have salt added
every 80 days (30
lbs/cell / [1.5 lb/day * 6 hr / 24
hr]).
Salt replenishment in the
salt reservoir requires the drainage of the brine, flushing
the anode compartment with water, and addition of new salt and
water to the brine reservoir. Adding of salt to the
cell without flushing and cleaning is not recommended for
several reasons. First, the anode compartment
contains residual chlorine gas that will be displaced when
salt is added. The amount of chlorine gas in this space
is small (0.05 lbs); however, this amount of chlorine gas is
irritating especially if in a confined space. Second, the
brine contains concentrated mineral impurities that will foul
the membrane at a more rapid rate if it is not removed.
It is also recommended that the membrane be cleaned during a
salt replenishment cycle which will increase the membrane's
life.
Replenishing the salt
consists of:
- Turn off the power supply to the
cell.
- Add roughly 1/2 gallon of sodium
hydroxide to the salt reservoir (few ounces for the 0.2
model). The sodium hydroxide will neutralize the
residual chlorine in the brine and make a salt saturated
hypochlorite solution.
- Drain the brine solution to waste and
flush out the cell removing all the residual matter in the
bottom of the cell.
- Add new salt and water to the anode
compartment (it is desirable to use softened water to
reduce the mineral fouling of the membrane).
- Place system back into
service.
Sodium
Hydroxide Dilution
SAFETY: Please note that sodium hydroxide is corrosive and
irritating to the skin. If sodium hydroxide touches the
skin, wash with water immediately to prevent chemical
burn. Wear protective clothing such as rubber gloves and
goggles when handling sodium
hydroxide.
The i-chlor chlorine generator requires
periodic dilution of the sodium hydroxide. Dilution can
be done manually, or automatically. For every 50 lb bag
of water softener salt, approximately 60 gallons of 10
percent sodium hydroxide solution is made. For every
1-pound of chlorine made, 2 gallons of 10 percent NaOH is
made. The actual amount of sodium hydroxide produced is
dependent upon the level and frequency of dilution. Using
the same 80-day operational cycle as discussed above, approximately 0.75
gallon of sodium hydroxide solution is produced every day of
operation.
Manual
Dilution:
Dilution of sodium hydroxide
in the cathode compartment requires the removal of
approximately one-half gallon of sodium hydroxide and the
addition of dilution water to the top overflow of
the cathode compartment (Note: more sodium hydroxide is
produced than water added for dilution). Water can also
be directly added to the cathode reservoir with excess
overflowing through the overflow and into the vacuum
relief reservoir, or other reservoir. It is
desirable to use softened water for the dilution to reduce the
mineral fouling of the membrane.
Maintenance of the sodium hydroxide
solution within the optimum range (10 percent or less)
provides extended life of the membrane. Daily testing of
the sodium hydroxide solution with a hydrometer will verify
the need to dilute the sodium hydroxide. The
following table illustrates the specific gravity and
concentration of sodium hydroxide at a temperature of 60
degrees F (15.5 degrees C):
|
%
NaOH |
Specific
Gravity |
|
2 |
1.023 |
|
4 |
1.045 |
|
6 |
1.067 |
|
10 |
1.090 |
|
12 |
1.112 |
|
14 |
1.134 |
|
16 |
1.156 |
|
18 |
1.178 |
|
20 |
1.201 |
|
22 |
1.223 |
Dilution of the sodium hydroxide consists
of:
- Turn off the power supply
to the cell.
- Removal of 1/2 gallon of
solution (or more if operating the cell at higher rates or
longer periods of time), and dispose/store as desired (this
could be disposal down a sanitary drain if solution is not
needed; however, sodium hydroxide is needed for pH
adjustment in the pool, CIP cleaning, lift station cleaning
in sewer systems, and/or pH adjustment of water
for lead and copper corrosion control in municipal
drinking water).
- Add dilution water
(preferably softened water) to a level at the top overflow
of the cathode compartment.
- Place system back into
service.
- Check small amount of solution daily with a
hydrometer.
Automatic Dilution:
The i-chlor system can be equipped with an
optional automatic density control system.
Excess sodium hydroxide is captured through the
vacuum relief reservoir, or in a separate system (i.e.
tank/jug) as desired.
