Hella Water HCCL-15KG/H Sodium Hypochlorite Generator Project Case

1. Case Basic Information

1.1 Project Subject

• Provider: HELLA WATER is a trusted manufacturer of high-performance water treatment solutions, specializing in the R&D and production of sodium hypochlorite generators and supporting systems. It offers a comprehensive range of water treatment product tailored to industrial, agricultural, and municipal needs.
• Core Product: HCCL-15KG/H series sodium hypochlorite generator

1.2 Product Model & Key Parameters

Parameter	Specification
Model	HCCL-15KG/H
Rated Available Chlorine Output	15,000 g/h
Available Chlorine Concentration	6,000~8,000 ppm
Brine Concentration	3~5%
Power Supply	380VAC, 50Hz, 3-phase
Electrode Material	TA1 pure titanium substrate (coated with ruthenium and iridium oxide)
Electrolytic Cell Type	Plate electrode tubular electrolytic cell (transparent and visible)

1.3 Application Scenarios

The HCCL-15KG/H sodium hypochlorite generator is widely used in water disinfection scenarios requiring high safety and efficiency, including:

• Municipal water supply disinfection (to meet drinking water hygiene standards)
• Industrial wastewater treatment, where it integrates seamlessly with professional sewage treatment machine to ensure compliant effluent discharge
• Agricultural water purification (e.g., pre-treatment of irrigation water to remove contaminants)
• Circulating cooling water sterilization in industrial parks to prevent microbial growth

1.4 Design Standards

The project is designed and manufactured in strict compliance with the following national and industrial standards:

Standard Number	Standard Name
GB 5749-2006	Hygienic Standards for Drinking Water
GB 12176-90	Standard for Sodium Hypochlorite Generators
GB 28233-2011	Safety and Health Standards for Sodium Hypochlorite Generators
GB 50231-98	Specifications for Construction and Acceptance of Mechanical Equipment Installation Projects
GB/T 3797-2005	Electrical Control Equipment

2. Project Core Pain Points & Requirements

2.1 Industry Common Pain Points

1. High Energy & Material Consumption: Traditional sodium hypochlorite generators consume over 5 kW·h of electricity and 4 kg of salt per kg of available chlorine, leading to unsustainable operating costs for long-term use.
2. Safety Risks: Hydrogen (a by-product of electrolysis) is prone to accumulation in poorly ventilated spaces, and the lack of real-time monitoring increases explosion hazards; additionally, chlorate content in effluent often exceeds the industry limit of 350 mg/L, failing to meet environmental regulations.
3. Operational Complexity: Manual intervention is required for critical tasks such as electrode pickling, chemical dosing, and fault diagnosis, resulting in high labor intensity and increased risk of human error.
4. Unstable Water Quality: Inability to dynamically adjust chlorine dosage based on real-time changes in water flow and residual chlorine levels leads to inconsistent disinfection—either substandard pathogen removal or excessive chlorine residues that affect water taste and safety.

2.2 Customer Core Requirements

• Energy Saving & Cost Reduction: Control the cost of producing 1 kg of available chlorine below 0.8 USD while reducing salt and electricity consumption to improve long-term operational efficiency.
• Safety Compliance: Meet international safety certifications including EU CE and German Rhine explosion-proof standards, and ensure hydrogen concentration remains below the safe threshold at all times.
• Intelligent Operation: Implement remote monitoring, automatic pickling, and real-time fault alarms to minimize manual intervention and streamline daily management.
• Water Quality Assurance: Ensure chlorate content in disinfected water is lower than the national standard of 0.7 mg/L, guaranteeing compliance with drinking water or industrial discharge requirements.

3. Hella Water Customized Solutions

3.1 Intelligent Control System

1. Full-Automatic Operation: Equipped with two-way IoT communication and precise algorithms that predict the operating status of key components in real time, enabling unattended operation and reducing human oversight.
2. Multi-Dimensional Monitoring: Supports remote cloud monitoring, PC-based networked collaboration, and mobile app control, seamlessly integrating with HELLA WATER’s industrial water filtration ecosystem for centralized management of water treatment processes.
3. Intelligent Maintenance: The system automatically detects electrode fouling based on operational data and completes pickling with a single click, reducing maintenance time by 60% compared to manual processes.
4. Fault Diagnosis: Real-time alarms are triggered for abnormal parameters (e.g., over-temperature, low liquid level, or irregular flow), and remote fault analysis tools help technicians resolve issues quickly without on-site visits.

3.2 Safety Assurance System

1. Certified Safety Design: The equipment has obtained German Rhine explosion-proof certification and EU CE certification, ensuring compliance with stringent international safety and health standards for industrial water treatment equipment.
2. Hydrogen Safety Protection:
   • A high-air-volume, high-pressure blower dilutes trace hydrogen (a by-product of electrolysis) to more than 100 times its original volume, reducing concentration to less than 1% before uniform discharge.
   • A multi-point, linked hydrogen monitoring system provides 24-hour real-time surveillance, with an alarm concentration set at 0.25% to prevent accumulation risks.
3. Water Quality Safety Control: An optimized electrolysis process minimizes chlorate formation, with the generator’s effluent containing ≤290 mg/L of chlorate—far below the industry limit of 350 mg/L and ensuring compliance with post-disinfection standards.

3.3 Energy-Saving & Cost-Reduction Design

1. High-Efficiency Electrolysis Unit:
   • Utilizes Dutch Machnetor electrodes (a global leader in anode technology) with a low chlorine evolution potential of 1.12V, significantly reducing power consumption.
   • Bipolar series-connected electrolytic cells minimize contact power loss by 15%, enhancing overall energy efficiency.
2. Precise Dosing Control:
   • Adopts PID closed-loop control combined with advanced algorithms (constant flow control, water volume control, and water volume-residual chlorine linkage) to adjust chlorine dosage dynamically.
   • Reduces invalid dosing by 20% compared to traditional systems, avoiding waste while maintaining consistent water quality.
3. Cost Optimization: The cost of producing 1 kg of available chlorine is only 0.72 USD, breakdown as follows: salt (0.32 USD) and electricity (0.4 USD), achieving significant savings for customers.

3.4 Core System Configuration

System Module	Composition	Key Functions
Electrolysis System	Transparent tubular electrolytic cell, Machnetor electrodes	Generate sodium hypochlorite (6,000~8,000 ppm) via diaphragmless DC electrolysis; transparent design enables visual monitoring of electrolysis progress
Hydrogen Exhaust System	CX-125A explosion-proof fan, IFM air flow monitor	Dilute and safely discharge hydrogen; real-time monitoring of air volume and pressure to ensure system stability
Acid Flushing System	PE acid tank (500L), acid pump (flow ≥2.5 m³/h)	Automatic online pickling of electrodes; no manual disassembly required, reducing maintenance workload
Dosing System	Ailipu JZM-A3000/0.3 metering pump, Keda electromagnetic flowmeter	Precise delivery of sodium hypochlorite to designated disinfection points; flow and pressure stability ensured by system accessories (safety back pressure valve, pulse damper)

4. Project Effectiveness Verification

4.1 Water Quality Compliance

• Chlorate Content: The chlorate content in the generator’s effluent is ≤290 mg/L; after being added to water bodies for disinfection, the final chlorate content is ≤0.5 mg/L—28.6% lower than the national standard of 0.7 mg/L.
• Disinfection Efficacy: The available chlorine concentration of 6,000~8,000 ppm ensures that the total number of bacteria in treated water is ≤10 CFU/mL, fully meeting the requirements of GB 5749-2006 “Hygienic Standards for Drinking Water” and industrial discharge regulations.

4.2 Energy & Cost Reduction

Index	Traditional Equipment	HCCL-15KG/H Generator	Reduction Rate
Salt Consumption (kg/kg·Cl)	≥4.0	≤3.2	20%
Power Consumption (kW·h/kg·Cl)	≥5.0	≤4.5	10%
Cost per kg of Available Chlorine (USD)	≥1.0	0.72	28%

4.3 Safety Performance

• Hydrogen Control: The hydrogen concentration in the operating environment remains consistently below 0.25% (the alarm threshold), eliminating accumulation risks; the system’s explosion-proof design has been validated by German Rhine certification.
• Operational Safety: Equipped with multiple protection mechanisms, including leakage protection, over-temperature protection, and liquid shortage protection; no safety accidents were reported during 10,000 hours of continuous field operation.

4.4 Operational Efficiency

• Intelligent Operation: Remote monitoring and automatic pickling reduce manual labor requirements by 80%; the system can run unattended for 72 hours continuously, improving productivity for busy facilities.
• Fault Handling: Remote fault diagnosis shortens troubleshooting time from 4 hours (traditional equipment) to 30 minutes; the average equipment uptime rate reaches 99.5%, minimizing production downtime.

5. Case Corresponding Product Quotation Description

5.1 Quotation Overview

No.	Product Description	Quantity	Unit Price (USD)	Total Amount (USD)
1	Sodium hypochlorite generator (Model: HCCL-15KG/H)Included modules:① Host system ② Dilute brine preparation system ③ Tap water pretreatment system (optional) ④ Raw material transportation, storage and dissolution system ⑤ Sodium hypochlorite solution storage system ⑥ Post-chlorination dosing system ⑦ Hydrogen exhaust system ⑧ Storage and discharge hydrogen dosing unit control system ⑨ Acid flushing system ⑩ Valves and fittings	3 sets	66,900	200,700

5.2 Quotation Terms

Term Type	Details
Validity Period	20 working days from the date of quotation
Payment Terms	40% advance payment, 55% before shipping, 5% after installation and acceptance
Lead Time	30 days (from receipt of advance payment to product delivery)
Incoterms	EXW (Ex Works) – customers are responsible for arranging shipping and customs clearance
HS Code	842199
Country of Origin	China
Product Condition	Brand new, with original factory testing certificates
Warranty Period	12 months since delivery (or 14 months after equipment arrival at the site, whichever comes first)

5.3 Additional Notes

• The tap water pretreatment system is optional and recommended for customers with feed water hardness exceeding 100 mg/L (as CaCO3); the quotation can be adjusted based on specific water quality requirements.
• The quotation does not include on-site installation, commissioning, or training services; these can be provided at an additional cost upon request.
• Spare parts (e.g., electrodes, filters, and valves) are available at preferential prices during and after the warranty period, ensuring long-term equipment operability.

6. Frequently Asked Questions (FAQ)

6.1 Installation & Commissioning

Q: What are the on-site installation requirements for the equipment?A: Each set of equipment requires an indoor installation space of at least 10 m², with access to a 380V 3-phase power supply, stable water pressure (0.3~0.6 MPa), and adequate ventilation. Installation must comply with GB 50231-98 “Specifications for Construction and Acceptance of Mechanical Equipment Installation Projects”. We provide detailed installation drawings, user manuals, and online technical guidance; on-site commissioning services can be arranged for an additional fee to ensure optimal system performance.

6.2 Maintenance & Upkeep

Q: How often does the electrode need to be replaced?A: The Dutch Machnetor electrodes have a service life of at least 8,000 hours under normal operating conditions (using 3~5% brine and regular pickling). The system automatically alerts users to pickling cycles (typically every 3~6 months, depending on water quality), which helps extend electrode life by up to 30%. Replacement electrodes are available directly from HELLA WATER at competitive prices.

Q: What is the frequency of routine maintenance?A: Routine maintenance tasks include weekly inspections of brine and acid tank levels, monthly cleaning of inlet filters to prevent clogging, and quarterly calibration of flowmeters and sensors to ensure accurate readings. The automatic pickling system eliminates the need for manual electrode disassembly, significantly reducing maintenance complexity.

6.3 Warranty & After-Sales

Q: What is covered under the warranty period?A: Within the 12-month warranty period, we provide free repair or replacement for any faults caused by design defects, manufacturing errors, or substandard materials. This excludes damage resulting from improper operation, neglect, or unauthorized modifications. The warranty period starts from the date of product delivery or 14 months after arrival at the customer’s site—whichever comes first.

Q: How can I access after-sales support if issues arise?A: We offer 24/7 technical support via email (info@hellawater.com). For emergency faults, our team responds within 2 hours and provides remote diagnosis to resolve issues quickly. For complex problems that require on-site assistance, we coordinate with local service partners to dispatch technicians (additional fees apply for non-warranty services).

6.4 Operational Cost

Q: What is the estimated monthly operating cost for a single set of equipment?A: Based on 8 hours of daily operation (producing 120 kg of available chlorine per day), the monthly operating costs are approximately: salt (1,152 USD) and electricity (1,296 USD), totaling around 2,448 USD. These costs may vary slightly depending on local salt and electricity prices, as well as actual operating hours.

6.5 Safety & Compliance

Q: Does the equipment meet international safety and environmental standards?A: Yes. The equipment is certified to EU CE safety standards and German Rhine explosion-proof standards, and complies with GB 28233-2011 “Safety and Health Standards for Sodium Hypochlorite Generators”. Its hydrogen exhaust system and low chlorate production technology fully meet global environmental protection requirements, making it suitable for use in regions with strict regulatory standards.