On-site chlorine generation systems are widely used in municipal and industrial water treatment due to their safety, reliability, and cost efficiency. However, like any electrochemical system, improper design, operation, or maintenance can lead to performance issues.
This article summarizes the most common problems encountered in on-site chlorine generation systems and provides practical solutions to help operators maintain stable and efficient operation.
Problem 1: Low Chlorine Output
Possible Causes
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Incorrect brine concentration
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Degraded or fouled electrodes
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Insufficient power supply or current
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Scaling or blockage in the electrolysis cell
Solutions
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Check and adjust brine concentration according to system design
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Inspect electrode condition and clean if necessary
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Verify power supply parameters and rectifier output
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Perform regular flushing and maintenance of the electrolysis cell
Consistent monitoring of operating parameters helps prevent output reduction.
Problem 2: Unstable Sodium Hypochlorite Concentration
Possible Causes
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Fluctuating brine feed rate
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Inadequate control system settings
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Variable water quality
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Irregular operating cycles
Solutions
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Ensure stable brine preparation and dosing
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Use PLC-based automatic control for consistent operation
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Monitor raw water quality and pretreatment performance
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Operate the system continuously when possible
Stable operating conditions are essential for consistent disinfectant quality.
Problem 3: Excessive Hydrogen Accumulation
Possible Causes
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Insufficient ventilation
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Blocked hydrogen discharge lines
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Improper system enclosure design
Solutions
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Install proper hydrogen ventilation and exhaust systems
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Regularly inspect and clean discharge piping
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Use hydrogen detectors and alarm systems
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Ensure compliance with safety design standards
Hydrogen safety is a critical aspect of on-site chlorine generation system design.
Problem 4: Rapid Electrode Wear or Short Service Life
Possible Causes
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Poor electrode coating quality
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Excessive current density
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Operation outside design parameters
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Inadequate cooling
Solutions
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Select high-quality MMO-coated titanium electrodes
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Operate within recommended current density range
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Ensure effective cooling and temperature control
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Follow manufacturer operation guidelines
Proper electrode selection and operation significantly extend system service life.
Problem 5: Scaling and Fouling in the System
Possible Causes
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Hard water or high mineral content
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Insufficient pretreatment
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Infrequent cleaning cycles
Solutions
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Install appropriate water softening or filtration systems
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Implement routine cleaning and inspection schedules
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Monitor water quality parameters regularly
Preventive maintenance is more effective than corrective maintenance.
Problem 6: High Operating Cost
Possible Causes
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Inefficient system design
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Oversized equipment
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Excessive energy consumption
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Poor control strategy
Solutions
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Optimize system capacity based on actual chlorine demand
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Improve automation and flow-paced dosing control
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Review energy efficiency of the rectifier and power supply
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Work with an experienced manufacturer to optimize system configuration
A properly designed system minimizes long-term operating costs.
Best Practices for Reliable Operation
To ensure long-term stable operation of on-site chlorine generation systems, operators should:
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Follow recommended operating parameters
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Implement routine inspection and maintenance procedures
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Monitor key performance indicators such as chlorine output and energy consumption
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Train operators on system safety and operation
These best practices help maximize system reliability and lifespan.
When to Consider System Upgrade or Optimization
Facilities should consider system upgrade or optimization when:
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Disinfection demand increases
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Safety or regulatory requirements change
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Existing systems show frequent performance issues
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Operating costs become excessive
In such cases, high concentration sodium hypochlorite generators or upgraded control systems may provide improved performance and efficiency.
Conclusion
Most problems in on-site chlorine generation systems can be prevented or resolved through proper system design, correct operation, and routine maintenance. Understanding common issues and implementing appropriate solutions ensures reliable disinfection performance and long-term operational safety.
Call to Action
If your on-site chlorine generation system is experiencing performance or operational issues, contact Qingyau for professional technical support, system optimization, or customized sodium hypochlorite generation solutions.