Amid the global trends of energy transition and sustainable development, Kuwait, an oil-producing country in the Middle East, is confronted with the dual challenges of ensuring stable power supply and environmental friendliness. As a nation with a typical tropical desert climate, Kuwait endures extreme summer temperatures (up to 50°C), high-salinity seawater in the Persian Gulf (salinity ranging from 40,000 to 49,000 ppm), and frequent sandstorms—all of which pose severe biological fouling issues to the seawater cooling systems of power plants. Seawater electrochlorination technology, an innovative solution for on-site disinfectant production and precise control of biological fouling, has gradually emerged as a key technical choice for Kuwaiti power plants to address operational challenges, thanks to its high safety, controllable costs, and environmental benefits. This article comprehensively analyzes the application value and development prospects of seawater electrochlorination technology in Kuwaiti power plants from four dimensions: technical principles, application scenarios, practical cases, and benefit analysis.
1. Technical Adaptability: Why Do Kuwaiti Power Plants Urgently Need Seawater Electrochlorination Technology?
The operational pain points of Kuwaiti power plants are highly aligned with the core advantages of seawater electrochlorination technology, and this adaptability stems from the local unique natural environment and power generation needs. Firstly, over 90% of Kuwait’s electricity is generated by gas-steam combined cycle power plants, which rely on seawater cooling systems to dissipate the massive heat produced during unit operation. Taking Al Zour North Power Station as an example, its single-plant circulating water flow can reach 74,502 tons per hour. However, abundant microorganisms in the Persian Gulf seawater (such as barnacles, mussel larvae, and diatoms) form biofilms on the inner walls of condenser titanium tubes and pipelines, reducing heat exchange efficiency by 20%-30% and causing millions of dollars in annual power generation losses.
The traditional liquid chlorine disinfection method can temporarily inhibit biological growth but requires long-term procurement, transportation, and storage of highly toxic liquid chlorine. This not only entails leakage risks (in 2023, a Kuwaiti power plant was shut down for 3 days due to a liquid chlorine cylinder leak) but also demands additional investment in explosion-proof and anti-toxic equipment, resulting in high operational costs.
Seawater electrochlorination technology precisely addresses this contradiction. By electrolyzing seawater (or brine) to produce sodium hypochlorite (NaClO) on-site, it eliminates the need for transporting and storing external chemicals, fundamentally mitigating safety hazards. Its core principle is as follows: in the electrolytic cell, under the action of a DC electric field, chloride ions (Cl⁻) in seawater are oxidized at the anode to form chlorine gas (Cl₂), which then reacts with hydroxide ions (OH⁻) generated at the cathode to produce sodium hypochlorite. Finally, precise dosing achieves biological fouling control.
For Kuwait’s high-salinity seawater, this technology offers a unique advantage: higher seawater salinity increases electrolyte concentration, thereby improving electrolysis efficiency. In the Persian Gulf seawater with a salinity of 45,000 ppm, the current efficiency of seawater electrochlorination systems can exceed 90%—far higher than the 75% achieved in freshwater environments. This means Kuwaiti power plants can obtain more disinfectant with the same energy consumption.
Furthermore, the modular design and intelligent control features of seawater electrochlorination technology are well-suited to the operation and maintenance needs of Kuwaiti power plants. Considering the impact of local high-temperature and sandstorm conditions on equipment, mainstream seawater electrochlorination systems (such as De Nora’s SEACLOR® and Qingdao Shuangrui’s SACP®) adopt electrolytic cells made of duplex stainless steel (2205) or titanium alloy, paired with nano-ceramic coated electrodes. These systems can withstand temperatures of 50°C and sandstorm impacts with a concentration of 500 mg/m³, extending equipment service life to 8-10 years. Meanwhile, the integrated PLC control system can real-time monitor parameters such as seawater temperature, salinity, and residual chlorine concentration, and automatically adjust electrolysis current and dosing volume. In the pilot application at Sabiya Power Plant, the system stabilized the effective chlorine concentration in cooling water at 0.5-1.0 ppm through residual chlorine feedback control, reducing biological adhesion by over 85% and lowering the condenser end difference (a key indicator of heat exchange efficiency) from 8°C to below 4°C.
2. Practical Cases: On-Site Application of Seawater Electrochlorination Technology in Kuwaiti Power Plants
Although large-scale application of seawater electrochlorination technology in Kuwaiti power plants began after 2020, several benchmark projects have verified its technical feasibility and economic benefits. Among these, the application at Al Zour North Phase II Power Station is the most representative. As Kuwait’s largest gas-steam combined cycle power plant, it has an installed capacity of 2,700 MW and a supporting seawater desalination plant with a daily output of 120 million gallons. The biological fouling in its cooling system once required 4-5 chemical cleanings annually, with each cleaning costing over $500,000 and causing a 48-hour shutdown.
In 2022, the power station introduced a seawater electrochlorination system provided by Qingdao Shuangrui, adopting an integrated solution of "pretreatment + electrolysis + intelligent dosing":
- Pretreatment Stage: To address the high turbidity of Persian Gulf seawater (15% of particles larger than 0.04 mm), the system was equipped with self-cleaning filters and cyclone desanders to control the suspended solids concentration in incoming water below 5 mg/L, preventing sand from abrading electrodes.
- Electrolysis Unit: A parallel design of 6 sets of concentric tube electrolytic cells (CTE) was adopted, with each set having a chlorine production capacity of 50 kg/h and a total capacity of 300 kg/h—sufficient to meet the disinfection needs of 74,502 tons of circulating water per hour.
- Dosing Stage: Dual dosing points were set at the circulating water pump inlet and condenser inlet, and metering pumps were used to precisely distribute sodium hypochlorite, ensuring full-process biological control of the cooling system.
By 2024, the system had operated stably for 24 months, reducing the number of condenser cleanings to once a year, accumulating $6 million in maintenance cost savings, improving power generation efficiency by 2.3%, and increasing annual power generation by approximately 120 million kWh.
Another typical case is the "old system renovation" project at Sabiya Combined Cycle Power Plant. Built in 2005, the plant originally used liquid chlorine disinfection for its cooling system. In 2023, due to price hikes from liquid chlorine suppliers and stricter environmental regulations, it decided to introduce Siemens Energy’s OSEC® seawater electrochlorination system for renovation. Given the limited shutdown window (only 15 days each winter), the renovation plan adopted an "in-situ replacement" strategy: retaining the original dosing pipelines, replacing the liquid chlorine vaporization device with 3 sets of electrolysis units (each with a chlorine production capacity of 100 kg/h), and adding a hydrogen safety treatment system (including negative-pressure collection and catalytic combustion devices).
After renovation, the system not only met the emission standards of Kuwait Environmental Public Authority (KEPA) (residual chlorine emission ≤ 0.1 mg/L) but also realized remote monitoring via IoT modules—operation and maintenance personnel could real-time check parameters such as electrolytic cell voltage, current, and hydrogen concentration through a mobile APP, shortening the early warning response time from 2 hours to 15 minutes. According to plant data, after renovation, annual chemical procurement costs were reduced by $2.8 million, while gas consumption decreased by 1.8% due to improved heat exchange efficiency, resulting in an annual carbon emission reduction of approximately 5,000 tons.
Beyond large-scale power plants, seawater electrochlorination technology also demonstrates flexible adaptability in small and medium-sized captive power plants in Kuwait. For instance, a 300 MW captive power plant owned by KNPC (Kuwait National Petroleum Company), limited by site space for large equipment, chose a skid-mounted seawater electrochlorination system from Hunan Yuansheng Environmental Protection. This system integrated pretreatment, electrolysis, storage, and dosing units into 2 standard containers, covering an area of only 80 m² with a chlorine production capacity of 50 kg/h—sufficient for 15,000 tons of circulating water per hour.
The system adopted a low-energy electrolytic cell design (specific chlorine production energy consumption of 4.2 kWh/kg Cl₂) and was supplemented by photovoltaic power supply (accounting for 30% of total energy consumption) to further reduce operational costs. Since its commissioning one year ago, the biological blockage rate of the plant’s cooling system has dropped from 12% to 3%, and water pump energy consumption has decreased by 8%, verifying the economic viability of seawater electrochlorination technology in small-scale scenarios.
3. Benefit Analysis: Multi-Dimensional Value in Economic, Environmental, and Social Aspects
The application of seawater electrochlorination technology in Kuwaiti power plants not only solves the operational pain point of biological fouling but also creates significant value in economic, environmental, and social dimensions, providing technical support for the sustainable development of the local power industry.
3.1 Economic Benefits
The "cost reduction and efficiency improvement" advantages of seawater electrochlorination technology are particularly prominent. From a cost structure perspective, although its initial investment is 30%-50% higher than that of traditional liquid chlorine systems, its operational cost is only 50%-60% of the liquid chlorine solution, with an investment payback period typically controllable within 3-5 years.
Taking Al Zour North Phase II project as an example, the initial investment in the system was \(12 million. However, annual savings in maintenance costs (\)6 million), increased power generation revenue (\(4 million), and gas savings (\)2 million) resulted in a total annual benefit of $12 million, with a static payback period of only 1 year—far below the industry average.
Additionally, seawater electrochlorination technology extends equipment service life: the replacement cycle of condenser titanium tubes due to biological corrosion has been extended from 5-8 years to 10-12 years, and a single condenser (valued at approximately \(8 million) can create additional asset value of over \)4 million.
3.2 Environmental Benefits
Seawater electrochlorination technology aligns with the low-carbon development goals in Kuwait’s "2035 National Vision":
- Reduced Chemical Production and Transportation: Traditional liquid chlorine generates approximately 80 kg of carbon emissions per ton from production to transportation to Kuwait. In contrast, seawater electrochlorination technology achieves "zero-carbon transportation" through on-site production. Taking Sabiya Power Plant as an example, reducing liquid chlorine usage by 1,200 tons annually corresponds to a carbon emission reduction of approximately 96,000 tons.
- Precise Dosing for Lower Residual Chlorine Emissions: Due to low control accuracy, traditional liquid chlorine dosing often leads to excessive residual chlorine emissions (reaching 0.5-1.0 mg/L). Seawater electrochlorination systems, however, can stabilize residual chlorine emissions at 0.05-0.1 mg/L through real-time feedback adjustment, reducing impacts on the marine ecology of the Persian Gulf.
- Hydrogen Recycling: Some projects have explored hydrogen recycling (e.g., Sabiya Power Plant uses electrolysis-generated hydrogen for boiler combustion support), further improving energy utilization efficiency and achieving an annual carbon emission reduction of approximately 2,000 tons.
3.3 Social Benefits
Seawater electrochlorination technology enhances the stability and safety of Kuwait’s power supply:
- Reduced Unplanned Shutdowns: According to statistics from Kuwait’s Ministry of Energy, before 2020, shutdowns caused by cooling system failures accounted for 25% of total power plant shutdown time. For plants applying seawater electrochlorination technology, this proportion has dropped to below 5%, significantly improving power supply reliability.
- Eliminated Toxic Chemical Storage Risks: Data from Kuwait’s Fire Department shows 12 chemical leakage accidents occurred in power plants between 2018 and 2022, 8 of which were related to liquid chlorine. No similar accidents have occurred since the commissioning of seawater electrochlorination systems, ensuring the safety of plant employees and surrounding communities.
- Local Capacity Building: Local cooperation in seawater electrochlorination technology (e.g., the joint venture between Qingdao Shuangrui and Alghanim Industries) has driven local employment and technological upgrading, cultivating a pool of professionals proficient in electrochemical water treatment.
4. Challenges and Prospects: Future Directions of Seawater Electrochlorination Technology in Kuwaiti Power Plants
Although seawater electrochlorination technology has achieved initial success in Kuwaiti power plants, it still faces challenges in technical adaptability, standards and specifications, and local capacity building during large-scale promotion—all of which need to be addressed through technological innovation and industrial collaboration.
4.1 Technical Challenges
Kuwait’s extreme environment imposes higher requirements on the long-term stability of seawater electrochlorination systems:
- High-Temperature Adaptation: Summer temperatures above 50°C can cause excessive heating of electrolytic cells, affecting electrode life. While existing systems control temperature through forced air cooling or water cooling, further optimization of heat dissipation design (e.g., adopting heat pipe technology) is needed to stabilize the operating temperature of electrolytic cells below 40°C.
- Scale Prevention: High concentrations of calcium and magnesium ions in Persian Gulf seawater (total hardness up to 1,500 ppm) tend to form scale on electrode surfaces, reducing electrolysis efficiency. Currently, this issue is addressed through regular acid cleaning (once every 3-6 months). Future solutions may include developing "anti-scaling electrode coatings" (e.g., nano-titanium dioxide coatings) or "online descaling systems" (e.g., ultrasonic descaling) to reduce cleaning frequency and maintenance costs.
4.2 Standards and Specifications
Kuwait has not yet developed dedicated standards for seawater electrochlorination technology, resulting in a lack of unified criteria for project design and acceptance. Currently, power plants mostly refer to international standards (e.g., IEC 62282, AWWA Standard B103) or standards from neighboring countries (e.g., Saudi Arabia’s KGS-0113). However, some provisions do not align with Kuwait’s actual environment (e.g., Saudi standards do not account for sandstorm impacts).
To address this, Kuwait’s Ministry of Energy is collaborating with KEPA and KNPC to develop the "Technical Specifications for Seawater Electrochlorination Systems in Power Plants," scheduled for release in 2025. The specifications will cover equipment material requirements (e.g., resistance to 500 mg/m³ sandstorms), performance indicators (e.g., current efficiency ≥ 85%), and safety standards (e.g., hydrogen concentration alarm threshold ≤ 1%), providing institutional support for technology promotion.
4.3 Local Capacity Building
Local capacity development is critical for the long-term development of seawater electrochlorination technology in Kuwait. Currently, local enterprises have the capacity for equipment installation and operation and maintenance, but core components (e.g., DSA® coated electrodes, IGBT rectifiers) still rely on imports, leading to long spare parts supply cycles (an average of 4-6 weeks).
To resolve this, international suppliers are accelerating local layout: De Nora plans to establish an electrode production base in Kuwait, while Qingdao Shuangrui has partnered with Alghanim Industries to build a spare parts warehouse (covering 80% of key components), shortening the spare parts response time to within 48 hours. Meanwhile, local universities (e.g., Kuwait University) have begun offering courses on "electrochemical water treatment" to cultivate professional talents and support industrial development.
4.4 Future Prospects
The application of seawater electrochlorination technology in Kuwaiti power plants will exhibit three key trends:
- Intelligent Upgrading: AI algorithms will optimize electrolysis parameters (e.g., predicting biological growth trends based on seawater temperature and salinity to adjust dosing volume in advance), further improving control accuracy. It is expected that biological control rates will exceed 95% within the next 5 years.
- Multi-Technology Integration: Seawater electrochlorination technology will be combined with ultraviolet disinfection, ultrasonic anti-scaling, and other technologies to form "synergistic treatment systems." For example, after sodium hypochlorite disinfection, ultraviolet light can further degrade residual chlorine, reducing impacts on marine ecology.
- Green Power Coupling: Kuwait’s abundant solar resources (over 3,000 hours of annual sunshine) will power seawater electrochlorination systems, achieving "zero-carbon disinfection." Currently, Sabiya Power Plant has piloted a photovoltaic-electrolysis coupling system and aims to achieve 100% green power supply by 2026, with an annual carbon emission reduction of approximately 8,000 tons.
The application of seawater electrochlorination technology in Kuwaiti power plants is a typical case of "technology adapting to needs and innovation solving pain points." This technology not only addresses the biological fouling challenges of power plants in local high-temperature and high-salinity environments but also provides a replicable model for the sustainable development of the power industry in the Middle East through its multi-dimensional value in economy, environment, and society.
Chlory Company has long been committed to the development and application of seawater electrochlorination technology. With continuous technological innovation, gradual improvement of standards, and enhanced local capacity, seawater electrochlorination technology is expected to become the mainstream technology for biological control in cooling systems of Kuwaiti power plants within the next 5-10 years. It will provide crucial support for Kuwait to achieve the low-carbon goals outlined in its "2035 National Vision" while contributing "Kuwaiti experience" to biological fouling control in coastal power.
The seawater electrochlorination systems developed by Chlory Company have been applied on a large scale in scenarios such as power plants, water supply plants, and sewage treatment plants in Middle Eastern countries including Kuwait, Iraq, and Iran. Relying on their outstanding performance and stable operation, these systems have won wide recognition from end-users.