← Watercalcs Estimates only — verify before relying on results. Estimates only · Terms of Use
Chlorine Storage & Dosing System Design
v2.2

Demand

Getting started

New to this tool? Turn on Worked example beside the page title. It fills every tab with a realistic set of values for a 120 L/s plant so you can explore. Turn it off and your own entries come back.

The tool sizes a full chlorination system, gas (cylinders or tonne drums) or sodium hypochlorite, from storage and withdrawal through dosing equipment to the contact tank and CT disinfection check. The tabs are independent views:

  • Demand: plant flow and applied dose give the design mass feed, which drives every other tab.
  • Gas Storage and Gas Dosing: container withdrawal, inventory, rotameter and ejector.
  • Hypo Decay and Hypo Dosing: product strength loss, chlorate, off-gassing and metering pump duty.
  • Contact & CT: contact tank baffling and disinfection credit.
  • Report & Save: PDF, CSV and a session file.

Start here by setting the plant flow and the chlorine dose you apply. Model basis and references are in About this model; tunable coefficients and design limits are in Settings. This tool provides guidance only: confirm credited values against current standards, manufacturer data and your compliance schedule.

Plant flow & dose

L/s
Average daily flow through the plant.
L/s
Highest sustained daily flow.
mg/L
Demand + target residual
mg/L
High-demand / storm event
Peak flow × peak dose is the usual sizing basis.

Supply form

Both sets of tabs stay available — this just notes your main supply.

Required chlorine mass feed

Average feed
– kg/day
Peak feed
– kg/day
Design feed (basis)
– kg/day
Design feed
– g/hr
ScenarioFlow (L/s)Dose (mg/L)Feed (kg/day)Feed (lb/day)
Mass feed = flow × dose. 1 mg/L at 1 L/s = 0.0864 kg/day. The design feed flows through to every sizing tab.

Gas storage

Guide: using this tab

Liquefied chlorine gas is drawn off as vapour, and the latent heat of vaporisation is pulled from the liquid and the container wall — so the container cools as you draw. Dependable continuous withdrawal is limited by how fast room air can put that heat back.

Set your container type, room temperature and how many containers run at once. The tool tells you the dependable withdrawal rate, whether your duty containers cover the design feed, and how much chlorine you are holding on site. Frost on a container marks where the wall has reached the air dew/frost point — the chlorine itself is not frozen (Cl₂ freezes at −102 °C).

The withdrawal-rate model (rated rate, temperature sensitivity, cut-off) is in Settings so you can tune it to your supplier's data.

Container & room

Presets the withdrawal model in Settings.
kg
About 70 kg for a cylinder, 900 kg for a tonne drum.
°C
Heated room target

Configuration & storage

no.
Containers feeding at the same time.
no.
Usually equal to duty, for automatic switchover.
days
At design feed, incl. delivery lead time
Liquid + evaporator removes the per-container gas-rate limit (heat supplied externally).

Withdrawal capacity

Per container @ temp
– kg/day
Total duty capacity
– kg/day
Design feed
– kg/day
Containers needed
– duty

Withdrawal rate vs room temperature

Solid line: per-container dependable rate. Dashed: per-container demand share at the current duty count. Where demand share exceeds the rate, containers frost and feed becomes unreliable — add containers or raise room temperature.

Storage inventory

Heat-transfer cross-check & short-burst capacity

Amber and red flags are prompts to look, not instructions to act.

Gas dosing equipment

Guide: using this tab

Vacuum gas dosing in three parts: a vacuum regulator on the container holds the line under vacuum, a variable-area rotameter (with a V-notch metering orifice) sets the gas rate, and an ejector uses motive water to entrain the gas into solution. The ejector's vacuum is what pulls gas through the whole train.

This tab sizes the rotameter full scale for your design feed, checks the turndown reaches your minimum feed, works out the minimum motive water for the ejector, and confirms the ejector has enough net operating pressure. Design limits (rotameter band, maximum solution strength, minimum net pressure) are in Settings.

Vacuum regulator / rotameter

kg/day
From Demand tab
kg/day
From the Demand tab or the % of design in Settings.
Average condition is the usual turndown check.

Ejector (injector) motive water

kPa
Pressure at the ejector inlet, typically 250 to 700 kPa.
kPa
Pressure at the point of injection.
Net operating pressure = inlet − back pressure. The minimum-acceptable value is set in Settings.

Rotameter / metering selection

Design feed
– kg/day
Min feed
– kg/day
Rotameter full scale
– kg/day
Turndown needed
– :1
Suggested full scale rounded up to a common chlorinator range (kg/day).

Ejector duty

Min motive water
– L/min
Solution at design
– mg/L
Net operating pressure
– kPa
Water at peak
– m³/h

Gas train schematic

Equipment checklist

Amber and red flags are prompts to look, not instructions to act.

Hypochlorite storage & decay

Guide: using this tab

Sodium hypochlorite slowly decomposes two ways at once: to chlorate (3 OCl⁻ → ClO₃⁻ + 2 Cl⁻) and to oxygen (2 OCl⁻ → 2 Cl⁻ + O₂). Available-chlorine loss is roughly second-order in strength, so stronger product decays faster, and the rate is strongly temperature-driven — roughly doubling every ~5 °C.

Enter your delivered strength, density, storage temperature and how long you hold product. The tool shows the strength and chlorate you can expect at the end of that period, the half-life, and how it all shifts with temperature. Because real decay depends heavily on trace metals and stabiliser, the rate constants are tunable in Settings, which also has a one-click calibration to back-solve them from a measured decay point.

Delivered product

% w/w
Delivered product is usually 10 to 15% w/w.
kg/L
About 1.2 kg/L at 15% w/w.
°C
Average temperature in the store.
days
How long product is held before use.
–
Rest → O₂

Storage tank

days
Bulk storage at design use, including delivery lead time.
Product held longer than about two weeks loses strength faster.

Strength & chlorate after storage period

Initial strength
– g/L
Strength @ period
– g/L
Available Cl₂ lost
– %
Half-life @ temp
– days
Chlorate in product
– g/L
k₂ @ storage temp
– L/mol/d

Available chlorine vs storage time

Curves at the storage temperature and ±10 °C show the strong temperature sensitivity. Second-order decay flattens as the solution weakens.

Strength & chlorate vs temperature (at period)

Temp (°C)Strength (g/L)Loss (%)Half-life (d)Chlorate (g/L)

Amber and red flags are prompts to look, not instructions to act.

Hypochlorite dosing & off-gassing

Guide: using this tab

As hypochlorite decomposes by the oxygen route it releases O₂. Those bubbles collect in suction lines and pump heads and break the prime of diaphragm metering pumps — "vapour lock". This tab estimates the off-gas rate and suggests a vent size, then sizes the metering pump.

The key sizing move: because product weakens with age, the pump is sized on the weakest (aged) strength so it can still deliver the dose, and we check the fresh-strength rate stays within turndown. The checklist below covers flooded suction, degassing heads and the other practical steps that keep a hypochlorite pump primed, and the vapour corrosion every hypochlorite plant room needs designed out.

Off-gassing (O₂ generation)

L
Product held in the bulk tank(s).
Uses strength, temperature, k₂ and the chlorate fraction from the Hypo Decay tab.

Metering pump sizing

kg/day
From Demand tab
% w/w
From the Hypo Decay tab.
% w/w
Aged product = higher pump rate
Dilution eases pumping but raises chlorate carry-over per kg and risks calcium scaling if carrier is hard.

Off-gas estimate

O₂ generation (initial)
– L/day
O₂ at temp +10°C
– L/day
Suggested vent area
– mmø
Indicative O₂ release from the oxygen-route fraction at the current temperature. Vent generously — rate climbs steeply with temperature and metal contamination.

Metering pump duty

Product @ fresh
– L/hr
Product @ aged
– L/hr
Pump capacity (design)
– L/hr
Daily product use
– L/day

Off-gas / vapour-lock mitigation

Amber and red flags are prompts to look, not instructions to act.

Contact tank & CT

Guide: using this tab

A serpentine baffled contact tank gets closer to ideal plug flow as its flow-path length-to-width ratio rises. The baffling factor BF = t₁₀/T (the 10th-percentile residence time over the theoretical) is the fraction of contact time you can credit, and C.t credit = FACE × t₁₀. FACE (free available chlorine equivalent) equals the free chlorine below pH 8.00; at pH 8.00 and above it is lowered in proportion to the hypochlorous acid present (pKa taken at 10 °C). The Giardia and virus log credits use free chlorine × t₁₀, because the USEPA requirement already allows for pH.

Enter the tank geometry, the free chlorine residual, temperature and pH, and your target Giardia and virus log credits. The tool returns the volume, theoretical and credited contact time, the CT achieved versus what's required, and the log removal you actually earn. The aim is to push BF toward 1 with high L:W, good inlet distribution and an outlet weir — then confirm the credited BF by a tracer test.

Tank geometry (serpentine)

L/s
Highest hourly flow through the tank.
no.
Passes in the serpentine, typically 3 to 10.
m
Width of each channel.
m
Minimum operating depth (the CT basis).
m
Length of each pass.
The credited factor must be confirmed by tracer test.
t₁₀/T from a tracer test, 0.1 to 1.

Disinfection requirement

mg/L
Lowest free chlorine at the tank outlet, typically 0.2 to 2 mg/L. FACE is worked out from this and pH.
°C
Coldest water temperature (the worst case).
Highest pH (the worst case), 6 to 9.
Giardia log credit required.
Virus log credit required, often 4.

Hydraulics & baffling

Volume
– m³
Theoretical T = V/Q
– min
L:W ratio
– :1
Baffle factor
–
t₁₀ (credited)
– min
Velocity
– m/min

CT credit vs requirement

C.t achieved (FACE×t₁₀)
– mg·min/L
FACE at this pH
– mg/L
CT req. Giardia
– mg·min/L
CT req. virus
– mg·min/L
Giardia log achieved
–
Virus log achieved
–

Contact tank plan (serpentine)

– 180° turns. Higher channel count and L:W push the baffle factor toward plug flow.

Amber and red flags are prompts to look, not instructions to act.

Report & Save

Guide: using this tab

Everything you need to take your work away lives here — and only here. Choose which tabs to include, then export a clean PDF report, download the inputs and results as CSV, or save the whole session as a JSON file you can reload later.

Tip for the PDF: in your browser's print dialog turn Headers and footers off for the cleanest result. The report is laid out to keep result blocks together across page breaks and shows every value as text.

Choose what to include

Export

PDF and CSV cover the tabs ticked on the left. JSON always saves the whole session.


Session file (JSON)