On-Site Sodium Hypochlorite Generation for Power Plant Cooling Water
Purchased 10% sodium hypochlorite was replaced with on-site generation for circulating cooling-water disinfection at power-generation facilities in Uzbekistan.
Project facts
Confirmed Project Data
Only confirmed project values are shown. Unpublished operating inputs are omitted rather than inferred.
- Location
- Uzbekistan
- Industry
- Power generationCirculating cooling-water duty.
- Application
- Cooling-water disinfectionOn-site sodium hypochlorite generation and dosing.
- Available-chlorine output
- 1,000 / 2,000 / 4,000 g/hNominal output for the three system sizes.
- Equipment
- NaClO electrolyser systemsModels KSCL-1000, KSCL-2000 and KSCL-4000.
- Project year
- 2026Site acceptance activity took place in March 2026.
Site requirement
Project Challenge
The project had been using purchased 10% sodium hypochlorite for circulating cooling-water disinfection. Chemical-handling, solution-stability, cost and operating-control concerns led to the adoption of on-site generation.
Existing chemical route
The plant purchased and stored 10% sodium hypochlorite solution before dosing it into the circulating cooling-water system.
Handling and solution stability
The delivered chemical required hazardous-chemical controls, while available chlorine could decline with light, high temperature or acidic conditions, complicating storage and consistent dosing.
Treatment requirements
The goals were to support safety and environmental assessments, reduce long-term operating cost, maintain consistent disinfection and automate chlorine dosing.
Engineering response
Project Solution
Low-concentration sodium hypochlorite is generated on site by electrolysing prepared dilute brine, then stored and metered into the circulating cooling-water system.
On-site generation
A 3% dilute-brine feed enters the electrolytic generator, which produces sodium hypochlorite at 0.6-0.9% available chlorine.
Three output duties
KSCL-1000, KSCL-2000 and KSCL-4000 systems provide nominal available-chlorine outputs of 1,000, 2,000 and 4,000 g/h.
Integrated auxiliaries and controls
The system combines salt dissolution, electrolysis, solution storage, dosing, water softening, acid cleaning, hydrogen venting and detection, with flow and temperature alarms. Automatic dosing still depended on resolving residual-chlorine analyser instability during commissioning.
System relationship
Process / System Configuration
The system follows the sequence below. The complete site hydraulic diagram, storage volumes, dosing rate and target residual-chlorine setpoint are not published.
01 · Feed-water and brine preparation
Softened or RO-water supply is monitored for flow, while salt dissolution and dilution prepare the 3% brine feed for electrolysis.
02 · Electrolysis
The prepared brine passes through an electrolytic cell with a transparent PMMA shell, titanium-based DSA anode, titanium cathode, 2.0 mm electrode spacing and a PVDF inter-electrode gasket.
03 · Solution storage and dosing
Generated 0.6-0.9% sodium hypochlorite is transferred to storage and then metered to the circulating cooling-water disinfection point.
04 · Safety and maintenance systems
Hydrogen venting and concentration detection support gas management, while the acid-washing system supports electrolyser cleaning. Outlet temperature, electrolyte flow and inlet-water flow are monitored by alarms or interlocks.
Confirmed equipment
Equipment Supplied
The project uses three NaClO-electrolyser system sizes with auxiliary generation, storage, dosing, cleaning and hydrogen-management equipment.
On-site disinfectant generation
NaClO Electrolyser Systems
- Model
- KSCL-1000 / KSCL-2000 / KSCL-4000
- Quantity
- 7 projected; 3 in operation
The system also includes salt-dissolution, solution-storage, dosing, water-softening, acid-washing, hydrogen-venting and hydrogen-detection equipment. The linked KUOSI page covers the related equipment category; final model selection remains project-specific.
View equipment details
Site record
Implementation / Installation
Commissioning and provisional or partial acceptance activity took place in March 2026 at Qibray, Sirdaryo and Jizzax power-generation sites. Three of seven projected systems were in operation.
- 01
Commissioning checks
System functions and alarms were checked alongside operating tests, including maximum-capacity and automatic-mode test periods.
- 02
Site acceptance status
Qibray received partial acceptance, Sirdaryo received provisional acceptance and Jizzax received approval during the acceptance stage.
- 03
Residual-chlorine analyser follow-up
Residual-chlorine analyser fluctuation of approximately ±0.5 mg/L prevented automatic dosing during the acceptance stage. The later resolution status is not confirmed.
- 04
Return inspection and maintenance
A later visit checked electrolytic cells, piping, flow, instrumentation and other components, and included cleaning of deposits observed on cell surfaces.
Operating outcome
Project Results
The available outcome data includes one measured available-chlorine test and qualitative operating observations. Treated-water flow, microbiological removal data, verified savings, ROI and a final automatic-dosing acceptance result are not published.
- Available chlorine test
- A later test measured 7,786 mg/L available chlorine, equivalent to approximately 0.77% and within the 0.6-0.9% generated-solution range.
- Continuous service
- Customer feedback described low electricity use, stable automation and reliable 24-hour continuous service. Site-measured energy-consumption data is not published.
- Maintenance observation
- Surface deposits and discoloration were associated with mineral content or local water conditions and did not affect available-chlorine output or normal operation after maintenance.
- Control-system limitation
- Analyser instability remained open during commissioning. Subsequent acceptance of closed-loop automatic dosing is not confirmed.
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