Overview
This 50 TPD sodium hypochlorite plant is a full-scale continuous production system built for heavy industrial and municipal mega-projects. Its rated condition is 50 tons of 12% sodium hypochlorite liquid per day, with flexible concentration tuning from 5% up to 15% NaClO. It runs on proven ion-exchange membrane brine electrolysis, consuming only industrial salt, softened feed water and grid electricity.
For facilities with massive chlorine demand, buying bulk delivered bleach creates persistent operational headaches. Long-distance haulage of hazardous bleach carries high freight, supply chain delays, and measurable strength degradation during transit and tank storage. Operating this 50TPD line on-site lets you produce fresh hypochlorite on demand, lock the exact chlorine strength your process requires, and remove dependence on third-party chemical suppliers.
This is not a simple skid-mounted generator. It is a complete engineered process package, including brine softening & preparation unit, multi-group electrolyser bank, high-power DC rectifier station, closed cooling circulation, hydrogen extraction & safe venting system, finished hypochlorite buffer tanks and central control room. Designed for stable 24/7 year-round continuous operation. Modular containerized layout is available for remote sites without permanent factory buildings.
Common buyers are large municipal water & wastewater groups, pulp & integrated textile bleaching complexes, major oilfield produced water treatment stations, industrial park central disinfection centres and large mining operations.
Core Specs
| Specification | Detail |
|---|---|
| Rated daily output | 50 ton/day sodium hypochlorite liquid @ 12% concentration |
| Adjustable concentration range | 5% ~ 15% NaClO |
| Fixed daily available chlorine | 6,000 kg/day |
| Core technology | Ion-exchange membrane brine electrolysis |
| Raw materials | Industrial salt (NaCl ≥89%), softened fresh water, electricity |
| Standard consumption | ~2 kg salt, ~2.5 kWh DC power per kg available chlorine |
| Control system | PLC + touch screen, native DCS / SCADA communication, full safety interlock, alarm logging & remote access |
| Wetted materials | CPVC piping, 316L stainless steel, fluorine rubber gaskets, titanium coated electrode |
| Layout | Multi-skid integrated process package; modular containerized option |
| Floor space | 320 ㎡ |
| Unit total weight | 26 ton |
| Warranty | 12 months full package; extended warranty package for ion membrane stacks & electrode banks |
| Field support | Complete civil & utility drawing package, on-site installation supervision, commissioning, multi-shift operation & maintenance training, 24/7 remote troubleshooting, regional service support in Africa, Middle East & Southeast Asia |
Output Table by Concentration (Fixed 6,000 kg/day available chlorine)
| NaClO Concentration | Daily Liquid Output |
|---|---|
| 5% | 120.0 TPD |
| 8% | 75.0 TPD |
| 10% | 60.0 TPD |
| 12% | 50.0 TPD (rated) |
| 15% | 40.0 TPD |
Important note: Total available chlorine capacity stays constant. Lower concentration settings deliver larger liquid volume; higher concentration reduces liquid throughput accordingly.
OPEX Breakdown (Reference, running at rated 12% mode, 24h continuous)
Calculated based on 6,000 kg available chlorine per day
- Salt consumption: ~12,000 kg/day industrial salt
- DC power consumption: ~15,000 kWh/day
- Water consumption: ~40 m³/day (brine softening, process & cooling make-up water)
- Consumable cycle: Ion membrane replacement every 2–3 years; electrode overhaul / re-coating every 3–5 years
- Labour: 2 shift operators + dedicated maintenance technician; unattended automatic run once stable
Actual running cost varies heavily by local electricity tariff, bulk salt pricing, water charges and raw water hardness. We can prepare a custom OPEX calculation sheet once you share local utility rates and site water analysis report.
Key Benefits
- Wide concentration flexibility. One full plant covers low-concentration municipal water disinfection and high-strength bleaching stock, no need to purchase separate bleach grades.
- Eliminates bleach degradation risk. Sodium hypochlorite naturally breaks down in storage; continuous on-demand production guarantees consistent available chlorine.
- Full layered safety protection suite. Continuous hydrogen concentration monitoring, brine low-level interlock, over-temperature protection, pressure relief, emergency stop and dedicated gas vent stack, mandatory for this scale of electrolysis line.
- DCS / SCADA ready. Supports Modbus and mainstream industrial protocols, seamless integration into site central plant control system for large facilities.
- Expandable modular design. If future chlorine demand rises, extra electrolyser stacks can be retrofitted to lift total available chlorine output without full civil reconstruction.
Typical Applications
- Large municipal drinking water & wastewater disinfection plants
- Pulp mill and integrated textile factory bleaching lines
- Oilfield & mining produced water treatment
- Industrial park circulating cooling water biocide control
- Large seafood & aquaculture cluster sanitation
- Central chemical supply station for heavy industrial zones
FAQ
Q: Can I switch between different concentrations while running continuously? A: Yes. Adjust brine feed and dilution setpoints on the control screen. Allow 60–90 minutes for the whole electrolyser bank, cooling and buffer system to stabilise before sampling and testing finished concentration.
Q: What extra site infrastructure does this 50TPD plant require compared with smaller 1/5/10/30TPD models? A: It requires a dedicated heavy-duty power transformer, full raw water softening pretreatment, independent hydrogen vent stack, hazardous chemical containment bund, fire protection and larger finished storage tank farm. We supply full civil, electrical and utility requirement drawings after order confirmation.
Q: What voltage and frequency options are supported? A: Standard 380V 50Hz; 415V, 440V, 480V / 60Hz versions available, rectifier cabinet will be custom matched to your local grid.
Q: How long will commissioning take for this large package? A: 10–14 working days on site, on condition that civil foundation, power supply, water supply and drainage are finished and accepted. Our engineers run full safety interlock testing, process tuning and multi-shift operation & maintenance training for your team.