Dairy Processor Replaces 2-Chem Chlorine Dioxide Generator

Electricide Electrochemical Chlorine Dioxide is Preferred Choice

Background – Chlorine Dioxide Disinfection

Dioxide Pacific recently provided an Electricide CDE-25 (472 g/hr – 25 pounds per day) electrochemical chlorine dioxide generator and dosing system to replace a traditional 2-chemical generator utilising 33% HCL and 25% sodium chlorite. This Australian dairy processor treats four water streams from the one generator including mains water and condensate.

Why Change?

The 2-chemical generator had ongoing reliability issues, plant room corrosion from HCL fumes and reduction in water alkalinity (pH). After an extensive evaluation process by an external consultant, the Dioxide Pacific Electricide electrochemical generator was chosen as the preferred replacement.

Advantages

The pertintent advantages of the Electricide generator are:

  • Use of only one precursor chemical
  • No acid – existing acid storage can be removed
  • Lower reduction in alkalinity (reduction in caustic use for pH correction)
  • Higher purity chlorine dioxide – no sodium, chlorite, chloride, chlorate added from the generator
  • Production of consistent 2,000 ppm ClO2 solution for dosing
  • Remote access via web server

System Description

In this system, chlorine dioxide solution at 2,000 ppm is produced in the generator solution tank and transferred via level control to a 1,500L FRP external storage tank. Four metering pumps dose from the outlet of this external tank to the four dosing points. Dosing is controlled from the generator HMI/PLC using different modes. There are three water storage tanks which are circulated. Each of the three tanks is controlled to a set ClO2 residual using PID control. One tank (mains water) also has flow paced dosing. Water entering the tank is dosed via flow pacing and the mains water in the tank is dosed to a PID setpoint. The combination of flow paced and PID provides accurate residual control.

Dioxide Pacific provided the complete system including generator, metering pumps, residual analyzers, chemical transfer system and storage tanks. Metering pumps with isolation valves, load valves, pressure relief valves and gauges were assembled on a skid. Analyzers and probe holders were mounted on a backboard. Electricide-P1 chemical is provided by Dioxide Pacific in IBC’s (totes). This chemical is formulated to provide chlorine dioxide conversion and long life for the electrolytic cell. The system was installed inside a purpose built shed by the customer.

Does this sound like something you could use?

Chlorine dioxide is ideal for disinfection of water used in food & beverage processing. You may be using chlorine or a 2-chemical chlorine dioxide generator for your water disinfection. If this information has piqued your interest, contact us for more information or a quotation.

Dioxide Pacific CDE-25 electrochemical chlorine dioxide generator.

Dioxide Pacific CDE-25 electrochemical chlorine dioxide generator. Generation of chlorine dioxide solution from single precursor chemical: Electricide-P1.

Electricide Electrochemical Chlorine Dioxide Generator for water disinfection

Electricide chlorine dioxide generator, dosing system and residual analyzers

Chlorine dioxide solution dosing skid

Chlorine dioxide solution dosing skid

Chlorine Dioxide for CIP Sanitization

Dioxide Pacific has supplied Electricide electrochemical chlorine dioxide systems for CIP sanitization in food and beverage applications with great results. In many cases, chlorine dioxide has replaced peracetic acid mixes. Typically, chlorine dioxide is applied at 1-3 ppm and can be dosed into the sanitisation rinse (flow paced) or made up as a 1-3 ppm solution (PID controlled) and pumped to through the system. Peracetic acid is typically used at 50-100 ppm.

One such food ingredient producer has been using the Electricide CDE10 generator for 3 years. They were using peracetic acid dosed from a tote (IBC) using a metering pump and paying $80k per year for chemicals. During connection of a tote, an operator came into contact with the chemical. Peracetic acid has a pungent vinegar smell which aggravates eyes and burns the skin (peroxide ingredient). Management decided to look around for an alternative and decided chlorine dioxide should be trialed. After 3 months of successful operation, the system was purchased and installed. Current yearly running costs are around $10k and the capital purchase was paid back in less than 1 year. The customer is happy with the improved safety aspects of chlorine dioxide as Electricide-P1 (the chlorine dioxide precursor) has no vapor and is easy to connect to the Electricide generator. Chlorine dioxide solution at 2,000 ppm is pumped to a CIP make-up tank where 3 ppm solution is made-up and controlled. The 2,000 ppm solution is safe to pump through UPVC pipe and the 3 ppm solution has no corrosion issues in stainless steel tanks and pipework. One benefit of the Electricide electrochemically generated chlorine dioxide is the purity of the solution produced – no chloride and close to neutral pH. Other methods of chlorine dioxide generation produce chlorine dioxide with low pH and high chloride which increase the risk of stainless steel corrosion.

Chlorine dioxide can be used as a final rinse as it will not react to form any odor or taint producing by-products in food and beverage products. This aspect will save a lot of water and energy. Usually, peracetic acid requires a lot of water as a post-rinse to remove the chemical. Chlorine dioxide does not require this post-rinse.

If you have a CIP sanitization application and would like to do the numbers on chlorine dioxide, contact Dioxide Pacific. Take a look at the features of the Electricide generator.