Powell Continuous Sodium Hypochlorite Dry Chlorine Process System

Powell's Continuous Bleach Plant will safely produce high quality bleach at a minimum operating cost. The system is constructed with the highest quality components available to ensure long service life with a minimum amount of maintenance. The plant is equipped with numerous safety devices which are intended to shut down the system in the event of a process upset. The plant is completely automatic and requires only that someone be available if a process upset occurs.

The systems are available in various production rates. Standard systems are rated for 1, 3, 6, and 9 short tons per hour of liquid chlorine. Systems using vapor chlorine will be de-rated. Each system has an adjustable production rate and is able to produce up to 200 grams per liter available chlorine.

The bleach strength and residual caustic levels are controlled at very high tolerances and can be adjusted at any time during production. The systems are designed for a completely automatic operation and can be started or stopped at any moment.

Powell Continuous Sodium Hypochlorite Dry Chlorine Process Systems are completely skid mounted on a structural steel frame approximately 20’ long x 8’ wide x 8’ high.

Bleach Plant


Bleach producers using the Powell Continuous System will considerably reduce the man-hours required to manufacture bleach in comparison to other bleach production processes. One operator can produce as much as 72,000 gallons of 160 grams per liter bleach in an 8 hour day.

The continuous system also offers major cost savings in raw materials due to its 99% plus efficiency when compared with a 93-96% efficiency experienced in batch operations. This increase in efficiency results in a decrease in the amount of sodium chlorate produced. The Material Balance On-Line Interactive Tool helps quantify these savings in efficiency.

Due to an extremely high repeatability of the continuous system, considerable savings are experienced from using fewer raw materials. Residual caustic levels can be lowered and final product strengths can be closer to the producer’s guaranteed strength, resulting in less product giveaway.

The type of cooling utilized by the continuous system also provides a major savings. Mechanical refrigeration is typically required with other processes. The Powell system utilizes cooling tower water for cooling resulting in considerable energy savings, lower equipment costs, and lower maintenance costs.

Utility and Raw Material Requirements

The basic utility and raw material requirements are as follows:

  • Dry liquid chlorine with a minimum pressure of 120 PSIG or dry vapor chlorine at a minimum pressure of 15 PSIG.
  • Sodium hydroxide at a pressure of 45-80 PSIG.
  • Process water (typically soft water) at a pressure of 45-80 PSIG.
  • Cooling water at a maximum temperature of 85° F.
  • Instrument quality dry air at a minimum pressure of 80 PSIG.
  • Three phase electricity for motors.
  • Instrument quality power for control system.

Materials of Construction

All units are constructed from the best materials available to maximize the service life of the system. Standard materials of construction are listed below. Other materials are available upon request.

  • Process water, caustic, and chlorine: Schedule 80 seamless steel pipe with 3000# forged steel fittings.
  • Cooling water: Schedule 80 PVC pipe and fittings.
  • Sodium Hypochlorite: Teflon lined steel pipe and fittings in high pressure areas and schedule 80 PVC pipe and fittings in low pressure areas.
  • Sodium Hypochlorite Pump: Titanium centrifugal pump with single mechanical seal.
  • Sodium Hypochlorite Recycle Tank: Steel tank with black chlorobutyl rubber lining.
  • Heat Exchangers: Plate and frame style with titanium plates and EPDM gaskets.

Construction Lead Time

Construction time for a continuous bleach system is typically six months. As a standard practice, Powell performs non-destructive testing on all assembled equipment before it is shipped. This includes mechanical inspections, process testing, process control testing, control panel and electrical testing, PLC program debugging, hydrostatic testing, and pressure testing. After delivery, the purchaser must make all raw material and electrical connections. After these connections are made, Powell technician(s) will perform additional water testing, startup, and training. Startup is typically performed in a relatively short time since the unit is completely tested at the factory.

Complete Line of Sodium Hypochlorite Processing & Filtration Systems

Whatever your sodium hypochlorite production volume, Powell can provide a Sodium Hypochlorite Processing System to meet your unique needs.