Abstract:
The “Solar powered chlorine producing module”, “SCPM”, is a multi-purpose invention. It is designed to provide daily use of chlorine and caustic soda for water and sewer treatment plants in municipalities throughout the world. This design reduces the operating cost of water and sewer plants in such a way that the initial capital cost will be captured within a few years. 
     This invention is designed to replace the chlorine producing plants which are expensive to build and costly to operate. They use enormous electric energy taken from already overloaded power grid. 
     This invention eliminates transporting chlorine, which is considered hazardous material from producing plant to end users&#39; sites. In addition to safety, it also eliminates the liquefaction and transportation cost. Currently, the chlorine end users need storage facilities for hazardous chemicals, which will be eliminated by use of the “SCPM” system. 
     Numerous industries use chlorine in daily processing and productions. They could use this system at their own site. Unlike conventional chlorine productions that are built with constant capacity production for their entire life with high initial capital cost, this design is flexible to the chlorine needs of user facilities. A chlorine production plant with “solar powered chlorine producing modules” is flexible, expandable with minimum initial capital investment that is suitable for any chlorine consumer facility.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to “solar powered Chlorine producing module” known as “SCPM” and, more specifically, to design a chlorine producing plant at the site of the municipalities&#39; water and sewer treatment plants or any other chlorine consumer industry. 
         [0003]    2. Description of the Related Art 
         [0004]    This invention utilizes the solar energy, a permanent, non-delectable and free source of energy. This invention is specifically designed to eliminate the dependence of new chlorine producing plant on power utility network. Chlorine and caustic soda (jointly) are among top ten chemical produced by chemical industries. Chlorine producing facilities, known as “chloric-alkali process plants” are one of the very high-energy consuming industry. Even partial elimination of conventional plants from power network lowers the stress of already overloaded power utility system. 
         [0000]    3. The present invention “SCPM”, unlike the conventional plant, does not run by power from the grid and does not need all the related power installation of high voltage service, step down transformer, converter of A/C power to DC power, and heavy conductor to carry very high electric current to electrolysis cells. DC Power generated by solar panel directly feed to chlorine producing cells. 
         [0005]    Any invention that eliminates or reduces the use of carbon base energy is advantageous to everyone. Reduction of dependence on oil imports and effects on the environment from burning fossil fuels are among the top benefits. More importantly though, and less discussed, is the fact that oil is a limited and deplete-able resource, one that is very valuable in the production of plastics, pharmaceutical, nylons, polyesters, pesticides and fertilizers, to name a few. 
         [0006]    Chlorine production in the site of municipalities&#39; water and sewer plants with this invention eliminates the handling, transportation and large storage facilities that are for chlorine, which is considered hazardous material. 
         [0007]    The saving from this invention is large enough to pay off initial capital investment of plant within five to ten years. 
         [0008]    Furthermore, the chlorine producing plant design with use of solar powered chlorine producing module, unlike the conventional plant, is environmental friendly. In this design, 2500 kWh of solar power will be used to produce one ton of chlorine. In conventional plant using utility power for each ton of chlorine, produced 5450 pounds of carbon dioxide will be released into the atmosphere by power plant, while CO 2  released by this invention is zero. The use of oil product to transport is eliminated. 
         [0009]    Finally, this invention utilizes the membrane technology that is superior among the three popular electrolysis process of chlorine production due to its lowest energy need per ton of chlorine produced (very high quality products and friendliest process to environment). 
       BRIEF SUMMARY OF INVENTION 
       [0010]    In an effort to improve the deficiencies of conventional chlorine producing plants, first objective of this invention is to provide a design that utilizes the solar energy to power the chlorine producing cells. 
         [0011]    The second objective of the present invention is to eliminate expensive electrical installation that receive high voltage A/C power from utility network, lower the voltage, and convert it from A/C to 3-volt DC current to power electrolysis cells. 
         [0012]    The third objective of the present invention is to eliminate the power loss in electrical installations and conversion. 
         [0013]    The fourth objective of this invention is to decrease stress on the electric network by eliminating high-energy users. 
         [0014]    The fifth objective of this invention is to eliminate rigidity in production and high initial capital cost of traditional plants by use of solar powered chlorine producing module “SCPM”. 
         [0015]    The sixth objective of the present invention is to eliminate transportation and storage of hazardous material on our roads and in the cities. 
         [0016]    It is a seventh objective of the present invention to use the membrane technology that has the lowest consumed energy the highest quality products. It is also most friendly process to the environment. 
         [0017]    It is a further objective of the present invention to use solar power and eliminate at least 2500 kWh from utility network for each ton of chlorine production that is equal to 5.9 barrel of crude oil not burned in power plants and less dependency to foreign oil. 
         [0018]    Finally, it is an objective of the present design to reduce the pollutants, which result from burning of fossil fuel in power generating plant and transportation. Traditional method for each ton of chlorine produced, power plant releases 5450 pound of carbon dioxide while the emission of CO 2  from this invention is zero. 
       SYMBOLS&#39; DESCRIPTION 
       [0019]    The following legend is provided at the opening of this section for easy reference when abbreviations are found throughout the detailed description section. Any abbreviation or symbols not in the legend are deemed to be known to those skilled in the art:
   Cl 2  is chlorine gas, a molecule of chlorine with two atoms   Cl −1  is ion of chlorine with negative charge of one electron   Na is one atom of metallic sodium   Na +1  is one ion of sodium with a positive charge of one proton, equal to charge of one electron but positive charge   H 2  is hydrogen gas   H +1  is ion of hydrogen.   e −1  is one electron with negative charge of 1.6022×10 −19  coulomb   Atom gram for any element, is the weight of 6.022×10 23  number atom of that substance in gram   Valence Gram is the atom gram of element divided by valence of that element   Valence is the degree of oxidation of element in chemical reaction. For example, Na +1 , Fe +2 , AL +3  are metals with 1, 2 and 3 valence, while Cl −1 , O −2  and p −3  are non-metal of 1, 2 and 3 valence   Coulomb is the electric charge passing through a wire having one AMP current in duration of one second   Farad is the electric energy needed to break down one valence gram of compound to its elements. One farad is equal to 96,485 coulombs   Na CL is sodium chlorine or table salt   Na OH is sodium hydroxide known as caustic soda in the market   Psi is unit of pressure and is equal to pound per square inch   C Coulomb   V, KV is volts and 1000 volt of power source   I is the current of power   Anion is Ion with negative charge like Cl −1 , O −2      Cation is Ion with positive charge like Na +1 , Fe +2      
 
       Science Behind 
       [0040]    To describe this invention, it is important that the solar technology and chemistry science on topic of electrolysis process be explained, and Prior to a detailed description of the invention, the following subjects need to be covered. 
         [0000]    A—Chemical science behind the electrolysis process, and popular methods in the chemical industry.
 
B—Science and technology of solar power.
 
         [0041]    Thereafter, the detailed description of invention becomes simpler and better understandable. 
       A—CHEMICAL SCIENCE BEHIND THE ELECTROLYSIS PROCESS 
       [0042]    What is chlorine? 
         [0043]    Chlorine is a substance that does not exist in nature but is abundant in compound form of metal chloride like table salt everywhere. 
         [0044]    Chemical Property: 
         [0045]    In chemistry science, chlorine is known as a member of one of the five elements of the Halogen group in periodic table. Its abbreviated symbol is “Cl”. Its atomic number is 17, and its atomic weight is 35.453 grams, and molecular weight of 70.906 gram. Chlorine usually forms compounds with a valence of (−1), but it can compound with a valence of (+1), (+2), (+3), (+4), (+5) and (+7). 
         [0046]    Physical Property: 
         [0047]    Chlorine is a greenish-yellow gas at room temperature and atmospheric pressure. It has the following physical properties:
       Melting point at atmospheric pressure (14.7 Psi) is −149.76° F. (−100.98° C.)   Boiling point at atmospheric pressure (14.7 Psi) is −29.15° F. (−33.97° C.)   Liquid state at room temperature of 60° F. has a pressure of 86.58 Psi   Specific gravity of Cl 2  respect to air at 32° F. and 14.696 Psi is 2.485 (note the density of dry air at the same condition is 1.2929 Kg/m 3      Specific gravity of Cl 2  liquid at 32° F. respect to 4° C. water is 1.467   Specific volume of Cl 2  gas at 32° F. and 14.7 Psi is 4.986F+ 3 /1b   Specific volume of liquid Cl 2  at 32° F. is 0.1092F+ 3 /1b       
 
       Use of Chlorine: 
       [0055]    Chlorine, along with its byproduct, caustic soda, is among the top ten products in the chemical industry. The world&#39;s chlorine production in 2014 was 56 million tons. Europe and North America&#39;s share were 16 and 11 million tons respectively. Presently, most chlorine is produced off site of the user industry. By this invention, the cost to liquefy the chlorine, bottling and shipment is eliminated. However, for chlorine to be used in water and sewer plants, it needs to be dried by passing it through concentrated sulfuric acid, then compressed and liquefied into cylinders for transportation. 
       Chlorine Production: 
       [0056]    In chemistry lab, chlorine can be produced in many ways but in the chemical industry, chlorine is produced by a breakdown of the chlorine compound (most commonly known as table salt, (Na Cl) by electrolysis of brine 
       Electrolyte: 
       [0057]    A solution of acid or alkaline or salts in water is called electrolyte. Electrolyte is conductive due to ions from ionization of one of the above substance in water. Ions Cl −1 , So 4   −2  and O −2  have negative charge and are known as “Anions”. Ions like H +1 , Na +1 , and Fe +2  have positive charge and are labeled as “Cations”. In electrolyte, anions and cations are mixed together randomly and uniformly. When electrolyte solution is placed in electrostatic field, separation and orientation of ions will happen and anions go to anode while cations head toward cathode. 
       Electrolysis: 
       [0058]    The process of separating the positive and negative ions in electrostatic field is called electrolysis.  FIG. 1  shows the concept of electrolyze process in the laboratory. Electrolyte  100  is a solution of Cl Na in water or solution of chloric acid and water  100 . Anode  101  and cathode  102  are connected to positive and negative of DC POWER  103 , Cl 2 ,  104  or  02104  is collected in anode  101 , H 2   105  and NaoH 106  in cathode  102 . The Process is described in the following equations: 
         [0000]      2ClNa→2Cl −1 +2Na +1  in electrolyte
 
         [0000]      2Cl −1 →Cl2+2 e   −1  in anode(Chlorine Ga s )
 
         [0000]      2H2O         2H +1 +2(OH) −1  in cathode 
         [0000]      2H +1 +2 e   −1 →H2 in cathode(Hydrogen Ga s )
 
         [0000]      2Na +1 +2(OH) −1 →2NaoH in cathode(Caustic Soda)
 
       Electrolysis Energy: 
       [0059]    In order to obtain chlorine, it is necessary to break the chemical bond of sodium and chlorine in salt solution by electric power input through the electrolysis process. One ion of chlorine (Cl −1 ) has a negative charge equal to the charge of one electron. When one ion of chlorine (Cl −1 ) is pulled toward anode, it will give up one electron to become one atom of chlorine gas. 
         [0060]    The electrical energy to produce one atom gram of chlorine is given in “Coulomb” by the following equations: 
         [0000]      [ C ] Energy (In Coulomb)=[Electric charge of one electron]×[Number of atoms in one atom gram of chlorine].
 
         [0000]    (C)=1.6022×10 −19 ×6.022×10 23 =96,485 coulomb. 
       Where 
       [0061]    1.6022×10 −19  is negative charge of one electron 
         [0062]    6.022×10 23  is Avogadro&#39;s No.=Number of atoms in one atom gram 
         [0063]    1 Farad is 96,485 Coulomb 
       Energy Input Per One Ton of Chlorine: 
       [0064]    The theoretical input energy is calculated by the following equations, 
         [0000]        C/ 1 ton Cl 2 =(96,485)×(10 6  gr/35.5 gr)=2.718×10 9 Coulomb/one ton Cl 2  
 
         [0000]        C   coulomb   =I   amps   ×t   sec  (Current×Time) or(Ampere×Second).
 
         [0000]    
       
      
       P 
       watt 
       =V×I 
       A 
       =V×C/t 
       sec  
      
     
         [0000]        P   watt /ton=3.3 v ×(2.718×10 9 Coulomb/ton Cl 2 )
 
         [0000]        P   KWH   =P   watt /(1000 watt/1 kw)×(3600 second/hour)
 
         [0000]        P   KWH   =P   watt /3.6×10 6  watt×second
 
         [0000]        P   KWH /ton=3.3 v ×(2.718×10 9  Coulomb/ton)/3.6×10 6  
 
         [0000]        P   KWH /ton=2492 KWH/one ton Cl 2    
         [0000]        P   KWH /ton=2492 KWH/one ton Cl 2    
         [0000]    In new membrane cells, the input energy per one ton of chlorine production is 2500 KWH. 
       Industrial Chlorine Production: 
       [0065]    Ninety-five percent (95%) of industrial chlorine production is by electrolysis of saturated salt solution. Now, three types of electrolysis cells, diaphragm cell, mercury cell, and membrane cell have been used extensively. The breakdown of brine is the same in all three, and their main difference is the manner by which their products are separated from the mixed and quality of the products. 
       A—Diaphragm: 
       [0066]    The diaphragm cell per  FIG. 2  and  FIG. 3  is made of brine Container  108  and permeable Diaphragm  107  that divides the Container  108  into anode Chamber  109  and cathode Chamber  110 . 
         [0067]    The saturated Brine  100  enters to anode Chamber  109  from the top. Brine elevation in anode Chamber  109  is higher than cathode Chamber  110  and create pressure drop across the permeable Diaphragm  107  to facilitate the movement of Brine  100  through Diaphragm  107  toward the Cathode  102 . In anode Chamber  109 , ion of Cl −1  goes to Anode  101 , and give up its electron and leaves anode as Chlorine gas  104  per  FIG. 1 ,  FIG. 2  and  FIG. 3  and the following equation. 
         [0000]      2Cl −1 →Cl 2 +2 e   −1  
 
         [0068]    In cathode Chamber  110 , water will be ionized to H +1  and OH −1 . Ion of H +1  receives one electron and as H2 gas  105  leaves the Cathode  102 , and ion of OH −1  combines with ion of Na +1  to produce Na OH  106 . 
         [0069]      FIG. 2  and  FIG. 3  show the reactions in cathode chamber per the following: 
         [0000]    
       
                 
         
             
             
         
       
     
         [0070]    In addition, in cathode Chamber  110 , the ion of Na +1  reaches the cathode,  102  receive the missing electron to become metallic sodium. Metallic sodium reacts with water and produce caustic soda  106  and hydrogen gas  105  according to the following equations. 
         [0000]    
       
                 
         
             
             
         
       
     
         [0071]    In the diaphragm, process chlorine gas  104  is collected at the top of anode Chamber  109 , and hydrogen gas  105  is collected at the top of Cathode Chamber  110 . 
         [0072]    The leaving solution  106  from cathode Chamber  110  contains about 10 to 12% Na OH (caustic soda) and 15% of Na Cl. By evaporation of diluted caustic soda  106  with steam and reduced its volume to 20% of original volume, when sodium chloride (Na Cl) crystallized and separates. The remaining solution containing 50% caustic soda and less than 1% Na Cl becomes marketable. However, the non-purified caustic solution  106  is suitable for 80% of market demand. 
       B—Membrane Cell: 
       [0073]      FIG. 4  and  FIG. 5  explain the ions orientation and chemical reaction in membrane cell. A non-permeable ion exchange membrane  107  divides the cell  108  into anode Chamber  109  and cathode Chamber  110 . Membrane  107  allows only the cation to pass through. 
         [0074]    Anode Chamber  109  includes anode  101  that is connected to positive pole of power source  103 . Saturated brine  100  enters in the lower part of the chamber. As it moves upward, it gives up its ions and anion Cl −1  attracts to anode  101 , gives one electron to anode and as chlorine gas  104  is collected at the top of Chamber  109 , depleted brine  116  leaves at the top of Chamber  109  to Brine concentrator  115 . 
         [0075]    Cathode chamber  110  has cathode  102  connected to negative power source  103 . Cathode Chamber  110  receives cation Na +1  from membrane  107 . Diluted caustic soda  106  by pure water  112  enters at the lower part of the chamber  110  moves up and gains additional “Na OH” becomes concentrated 33% caustic ˜ 113  when it leaves the cathode chamber  110 . 
         [0076]      FIG. 4  and  FIG. 5  show the movement of ions and chemical reactions. In anode chamber  109 , chlorine gas CL 2   104  produces from anion Cl −1  per the following equation. 
         [0000]    
       
                 
         
             
             
         
       
     
         [0000]    In cathode chamber  110 , hydrogen gas H 2    105  and sodium hydroxide (Na OH)  113  will be produced per the following reactions.
       a—In cathode  102  water molecules polarized and ionized with cathode&#39;s excess electrons.       
 
         [0000]    
       
                 
         
             
             
         
       
       
         
           
             b—Cation Na +1  reaches cathode  102 , receives one electron, becomes Metallic Sodium that reacts with water to produce hydrogen gas  104  and Caustic soda  113 . 
           
         
       
     
         [0000]    
       
                 
         
             
             
         
       
     
       C—Mercury Cell: 
       [0079]      FIG. 6  and  FIG. 7  show the schematic of mercury cell. It has a spread of mercury at the sloped bottom of the cell as cathode  102 . A row of metallic plates located at close distance of mercury surface act as anode  101 . The anodes and cathode share one chamber. Saturated brine  100  enter at the top at the level of the anode plates, and depleted brine  116  leaves at a level slightly higher than brine entry  100 . Negative power pole is connected to mercury cathode  102  through the bottom plate. Due to uniformity of electro-static field between cathode  102  and anode  101 , mercury cells are able to operate with higher current density as high as five and three times of the diaphragm and membrane respectively. In addition, the applied voltage can be 20% higher than the others can. For this reason, mercury cells have higher production per unit volume. Per  FIG. 6 , as saturated brine  100  enter cell  108 , anion Cl −1  attracts to the anode, strips its electron and at the top of the cell as chlorine gas  104 . Cation Na +1  go to mercury, receives electron and becomes metallic sodium (Na). In cathode  102 , mercury forms “Na—Hg Amalgam”  118  that leaves the cell  108  to amalgam decomposer  117 . As  FIG. 7  shows, in decomposer  117 , the amalgam comes in contact with ionized water  112 . It reacts with water and breaks down per the following equations. 
         [0000]      2H 2 O         2H +1 +2OH −1    
         [0000]      2H +1 +2 e   −1 →H 2 (Hydrogen gas)
 
         [0000]      2OH −1 +2Na—Hg→2NaOH+2Hg(Caustic Soda &amp; Metallic Mercury)
 
         [0000]    In decomposer unit  117 , hydrogen gas  105  will be collected at top of decomposer  117 , regenerated mercury  119  recycles back to mercury cell  108 , and caustic soda solution  113  goes to further purification if it is needed. Mercury cell caustic has the higher quality than the products of the other two Cells that was previously mentioned. However, there is 0.2 to 3 grams of mercury pollutant per each ton of chlorine. 
       Specification of Chlorine Cells 
       [0080]    The following table is the summary of the cell&#39;s specifications. It helps in better understanding and proper cell selection. 
         [0000]    
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
                   
               
               
                   
                   
                 MERCURY 
                 DIAPHRAGM 
                 MEMBRANE 
               
               
                   
                 DESCRIPTION 
                 CELL 
                 CELL 
                 CELL 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 Theoretical 
                     3.15 
                     2.19 
                     2.19 
               
               
                   
                 Voltage (V) 
               
               
                 2 
                 Current density 
                  8 to 13 
                 0.9 to 2.6 
                   3 to 5  (1)   
               
               
                   
                 (KA/m2) 
               
               
                 3 
                 Cell voltage (V) 
                 3.9 to 4.2 
                 2.9 to 3.5 
                 3 to 3.6 
               
               
                 4 
                 Caustic strength 
                 50% 
                 12% 
                 33% 
               
               
                   
                 (% by weight) 
               
               
                 5 
                 KWH of AC/one 
                 3360 
                 2720 
                       2650  (2)   
               
               
                   
                 ton of chlorine 
               
               
                   
                 in 
               
               
                 6 
                 Current density 
                 at 10 KA/m2 
                 at 1.7 KA/m2 
                 at 5 KA/m 2   
               
               
                   
                 of KA/m2 
               
               
                 7 
                 Electric energy 
                  200 
                  250 
                  140 
               
               
                   
                 used by other 
               
               
                   
                 equipment 
               
               
                   
                 (Compressor, 
               
               
                   
                 Pumps,) 
               
               
                   
                 ACKWH/ 
               
               
                   
                 ton of Cl 2   
               
               
                 8 
                 Total energy 
                 3560 
                 2970 
                 2790 
               
               
                   
                 used 
               
               
                   
                 (ACKWH/ 
               
               
                   
                 ton C1 2 ) 
               
               
                 9 
                 Energy used by 
                   0 
                  610 
                  180 
               
               
                   
                 steam to 
               
               
                   
                 concentrate 
               
               
                   
                 caustic soda to 
               
               
                   
                 50% (ACKWH/ 
               
               
                   
                 ton Cl 2 ) 
               
               
                 10 
                 Adjusted total 
                 3560 
                 3580 
                 2970 
               
               
                   
                 energy 
               
               
                   
                 (ACKWH/ 
               
               
                   
                 ton Cl 2   
               
               
                 11 
                 Caustic quality 
                 High 
                 1-1.5% Cl Na 
                 High: &lt;50 ppm 
               
               
                   
                   
                 2.5-25 mg of 
                 by weight after 
                 Cl Na 
               
               
                   
                   
                 Hg/Li Pollutant 
                 treatment 
               
               
                 12 
                 Chlorine quality 
                 &lt;0.1% of 
                 1.5-2.5% 
                 0.5-2% 
               
               
                   
                   
                 O 2  &amp; H 2   
                 oxygen 
                 depending on 
               
               
                   
                   
                 Oxygen &amp; 
                   
                 acidity of brine 
               
               
                   
                   
                 hydrogen 
               
               
                 13 
                 Requirement of 
                 Some High 
                 Some High 
                 Very High 
               
               
                   
                 purification of 
               
               
                   
                 brine 
               
               
                 14 
                 Variable electric 
                 30% of full 
                 slightly 
                 40-60% 
               
               
                   
                 load 
                 load possible 
                 variable 
                 full load 
               
               
                   
                 performance 
               
               
                 15 
                 Construction cost 
                 expensive 
                 relatively cheap 
                 cheaper than 
               
               
                   
                   
                   
                   
                 mercury 
               
               
                 16 
                 Operation 
                 toxic Hg must 
                 frequent 
                 low 
               
               
                   
                   
                 be removed 
                 asbestos 
                 maintenance 
               
               
                   
                   
                 from effluent 
                 replaced 
                 cost 
               
               
                   
               
               
                   (1)  Current density of 5 KA/m2 uses more energy but increase production. High density creates more heat. Warmer caustic and less steam is required. 
               
               
                   (2)  New membrane for first two years uses 2575 KWH/ton of chlorine. 
               
               
                 3 - The heat lease from one-ton steam when condensed in concentrator Unit is equal to 250 KWH. 
               
             
          
         
       
     
       Selection of Electrolysis Cell for this Invention 
       [0081]    After study of science behind the electrolysis and three popular chlorine-producing cells, the membrane technology has been selected with the following considerations.
       1—Pollution to environment: mercury cell releases 0.2 to 3.0 gram of mercury per ton of chlorine as pollutant. Diaphragm cells are made by spray of asbestos over metal mesh that contributes pollution when it is made or replaced.
           Membrane is environmental friendly.   
           2—Energy use: Among the three cells, the membrane has the lowest KWH used to produce one ton of chlorine.   3—Power voltage fluctuation: up to 40% does not affect the membrane&#39;s performance.   4—High quality product: Membrane products of Cl 2 , H 2 , Na OH are high quality and can be used directly without further purification.   5—Low capital investment: The membrane cell has low capital investment, low operating cost, the lesser environmental impact, and it is the best available technology (Bat).
 
In “solar chlorine producing module”, “SCPM”, the subject of this invention, the membrane has been selected for chlorine production.
       
 
       B—SCIENCE AND TECHNOLOGY OF SOLAR POWER 
       [0088]    Solar cell is a diode of semi-conductors that generate electric energy when irradiated by the sun&#39;s rays. Solar cells are often electrically connected and encapsulated as a panel that have a sheet of glass on the sun&#39;s side allowing the light to pass while protecting the semi-conductors from rain, hail and other elements. In solar panel, cells are connected in series for voltage increase and in parallel for current increase. An array is a group of cells that are electrically connected in parallel and series with desire DC voltage and current. The power output of solar array is measured in watts or kilowatts. To calculate the energy needed for an application, a measurement of KHW per day is often used. A common rule of thumb is that the average power over 24 hours is equal to 20% of pick power, so the solar panel energy production in 24 hours is equal to production of same panel with peak power in five (5) hours. The solar generated energy most often is fed into power utility network by using inverters. In stand-alone systems, batteries are used to store the energy that is not needed immediately. 
       Solar Cell Efficiency: 
       [0089]    Solar cell&#39;s “energy conversion efficiency” is the ratio of power converted to electricity divided by solar energy irradiated to solar cell&#39;s surface. The efficiency is calculated by the ratio of the maximum power point, (Pm watt ) of panel with area of Ac, (meter squared, M2) divided by the total panel sunlight power. The total panel sunlight power, P sunlight , is the sunlight power irradiance E, (E WATT /M 2 ) on panel area of Ac under standard test conditions (STC), per equation (1.) 
         [0000]    
       
         
           
             
               
                 
                   = 
                   
                     
                       Pm 
                       w 
                     
                     
                       E 
                        
                       
                           
                       
                        
                       w 
                        
                       
                         / 
                       
                        
                       
                         m 
                         2 
                       
                       × 
                       
                         Ac 
                         
                           m 
                            
                           
                               
                           
                            
                           2 
                         
                       
                     
                   
                 
               
               
                 
                   ( 
                   1 
                   ) 
                 
               
             
           
         
       
     
         [0000]    Standard test condition is temperature of 25° C., irradiance of E=1000 w/M 2 , and air mass of “A M 1.5” spectrum. 
       Air Mass Spectrum: 
       [0090]    The Air mass number varies, it dependent on geographic location, altitude, sun location and elevation. It varies with time of the day and with seasons of the year, it could have any value and because of that, it called AM spectrum. 
         [0000]    For a path length “L” through the atmosphere for solar radiation incident at angle “Z” relative to the normal to the earth&#39;s surface, the air mass coefficient is; 
         [0000]        AM=L/L   0 =1/Cos Z°
 
       Where; 
       [0091]    “L 0 ” is the Zenith path length (Atmosphere vertical length at the sea level).
 
“Z” is the Zenith Angle in degree.
 
For sun at angle “Z=48.19°.”
 
       AM=1/Cos 48.19°=1/0.66666=1.5 AM 
       [0092]      FIG. 8  depicts the irradiance and spectrum of sunlight incident of the surface of the solar panel  200  tilted 37° and sunlight at noon  205  at an angle of 41.81° above horizon. This condition represents almost the solar position near the vernal equinox and autumnal equinox in the continental United States, in clear day. The sun&#39;s irradiance energy will be 1000 w/M 2 . IN this condition, if the solar cell&#39;s power point is 150 watts then the efficiency of this cell is (150 w/1000 w  or 15%. 
       Maximum Power Point: 
       [0093]    A solar cell may operate over a wide range of voltage (V) and current (I) depending on the resistance of connected circuit. Circuit with zero resistance (short circuit condition) voltage is zero. Current is max called “I sc ” when circuit resistance increases to infinity (open-circuit), voltage has the highest value called “V oc ” and current is zero. At those two ends of resistance spectrum, solar power generated is zero, and will have value when both voltage and current have no-zero values. With certain circuit resistance, the power generated is max. This is known as power point (Pm). 
       Silicon Cell Max Voltage: 
       [0094]    A high quality mono-crystalline solar silicon cell may produce 0.6 volts (V 0 ) at cell temperature of 25° C. In ambient temperature of 25° C. and full sum, the temperature of irradiated cell will be about 45° C. This higher temperature reduces the voltage V oc  to 0.55 volts per each cell. 
       Maximum Power Point: 
       [0095]    At an ambient of 25° C. and silicon cell working temperature of 45° C., the maximum power is produced with voltage of 75% to 80% V oc  (say 0.43 volts) and the current is 90% of I sc  (short-circuit). Therefore, the maximum power point (Pm) is about 70% of “V oc ×I sc ”. 
         [0096]    Low quality cells have more rapid voltage drop with current increase and its power point voltage is 50% of Voc. Its current is 50% I sc , and the power point could drop from 70% of V oc ×I sc  to 50% or even 25%. 
       Solar Cell Selections: 
       [0097]    Use of power point (V oc ×I sc ) in solar cell alone as a guide in solar cell selection is misleading and insufficient. However, full spectrum of power generation curve with current increase should be considered. 
       Solar Cell Fill Factor (FF): 
       [0098]    The ratio of summation of power spectrum correspond to current from zero (I o ) to (I sc ), that is the area under power curve (in plot of power versus current), to power point of V oc ×I sc  is called Fill Factor. Fill Factor is useful in cell selection. 
         [0000]    
       
         
           
             
               
                 
                   FF 
                   = 
                   
                     Pm 
                     
                       
                         V 
                         oc 
                       
                       × 
                       
                         I 
                         sc 
                       
                     
                   
                 
               
               
                 
                   ( 
                   2 
                   ) 
                 
               
             
           
         
       
     
         [0000]    From equation 1, substitute, (Pm=m×E×Ac) in to equation (2) 
         [0000]    
       
         
           
             FF 
             = 
             
               
                 × 
                 Ex 
                  
                 
                     
                 
                  
                 Ac 
               
               
                 
                   V 
                   co 
                 
                 × 
                 
                   I 
                   sc 
                 
               
             
           
         
       
     
       Irradiance Effect on Power Production: 
       [0099]    The short circuit current (I sc ) is nearly proportional to illumination intensity. Open-circuit voltage (V oc ) is less sensitive to illumination. By 80% drop of illumination there is only 10% drop in open-circuit voltage (V oc ). 
       Range of Efficiency: 
       [0100]    Solar cell efficiencies vary from 6% (amorphous silicon base) to 40.2% and 42.8% (multiple junctions in research laboratories). 
       Commercial Sell: 
       [0101]    Commercially available multi-crystalline silicon cells have efficiency of 14% to 19%. 
         [0102]    The highest efficiency cells are not the most economical. Multi-junction cell with efficiency of 30% based on exotic materials such as “Gallium Arsenide” or “Indium Selenide” will cost 100 times of silicon cell with 8% efficiency and only produce four times the power. 
       Cost of Generated Power by Solar Panel: 
       [0103]    The price of delivered KWH is the way to justify the economic cost of power generated by solar cell. In cost analysis, the following dominating parameters should be considered: 
         [0104]    1. Efficiency conversion of solar panel 
         [0105]    2. Intensity of sun irradiation 
         [0106]    3. The useful life of solar panel 
         [0107]    4. Fill Factor (FF); the larger the number the better the cell 
         [0108]    5. Curve of power versus current 
         [0000]    The above parameters will lead to overall system selection between the choices. 
       Cost of Solar Power Versus Conventional Power Plant: 
       [0109]    With commercial silicon panel and efficiency of 8% to 19%, the cost of solar power in 2005 ranged from $0.6/kwh (Europe) down to $0.3/kwh (in regions with high sun irradiation). The large portion of above cost is due to cost of large conductors, low voltage DC power (direct current) to AC (alternative current) convertors, step up transformer, and synchronizing and metering equipment. Also in process of converting 30-volt DC power to AC, power with 20 kv volt (utility distribution voltage) over 30% of energy generated convert to heat as loss. Worldwide, the cost of conventional power plants in year 2005 was between $0-04/kwh to $0.25/kwh depending on plant size and fuel. 
         [0110]    Based on above argument, it can be concluded that use of solar panel to feed power utilities network is not feasible. 
         [0000]    Solar Power in this Invention: 
         [0111]    Chlorine producing cells use low voltage DC power (3 volts). To provide such power from high voltage utility network requires installation of expensive electrical equipment to lower the voltage and convert it from AC to DC power. This process associates with power loss of 30% and more, but solar panels generate exact power that is consumed by chlorine producing cells. 
         [0112]    In this case, the cost of delivering KWH to chlorine cell drops to less than $0.1/kwh that makes the use of solar power economically feasible. 
         [0113]    Solar Cell Selection for this invention: 
         [0114]    The solar cell technology is relatively spread in regards to: 
         [0115]    1. Costs, solar cells have price from low to very high 
         [0116]    2. Efficiency: the efficiency of solar cells ranges from 6% to 40% 
         [0117]    3. Durability: resistance against severe elements and ultra violet 
         [0118]    4. Life: useful life span 
         [0119]    Considering the above parameters, crystalline silicon “C—Si” is a good choice. Crystalline silicon also known as “solar grade silicon” is the most prevalent bulk material for solar panels with an average efficiency of 15%. A commercial solar panel of crystalline silicon “C—Si” model “LG265 Si—C 265G3” product line of “Monox”, with dimension of 65″×40″×1.4″, and efficiency of 16.4% with the following specification has been selected. 
       Selected Solar Pane Specification: 
       [0120]      
         [0000]    
       
         
               
               
             
               
               
               
             
               
               
             
               
               
               
             
               
               
             
               
               
               
             
               
               
             
           
               
                   
               
             
             
               
                 Model Number 
                 LG265 Si—C 265 G3 
               
               
                 Product Line 
                 Monox 
               
               
                 Dimensions (inches) 
                 64.57″ × 39.37″ × 1.38″ 
               
               
                 Dimensions (metric) 
                 165 cn × 100 Cn × 3.5 Cn 
               
               
                 Light Capture Area: Ft 2  (M 2 ) 
                 18 Ft 2  (1.65 M 2 ) 
               
             
          
           
               
                 Max. System voltage 
                 600 
                 volts 
               
               
                 System power rating (watts) 
                 265 
                 watts 
               
               
                 Watt (PTC) 
                 239.5 
                 watts 
               
               
                 Max Power voltage 
                 31.4 
                 volts 
               
               
                 Max Power current 
                 8.46 
                 amps 
               
               
                 Open Circuit voltage (V oc ) 
                 38.7 
                 volts 
               
               
                 Short circuit current (I sc ) 
                 8.92 
                 amps 
               
               
                 I sc  × V oc   
                 345.2 
                 VA 
               
             
          
           
               
                 Power rated/I sc  × V oc   
                 76.8% 
               
               
                 Watt (PTC)/I sc  × V oc   
                 69.4% 
               
             
          
           
               
                 Series Fuse rating 
                 15 
                 amps 
               
             
          
           
               
                 Panel Efficiency 
                 16.2% 
               
             
          
           
               
                 Watt/Ft 2   
                 14.72 
                 w/Ft 2   
               
               
                 Price $/Panel 
               
             
          
           
               
                 (E-bay average of 27 to 162 panels) 
                 $310/panel 
               
               
                 Price/Ft 2  ($/Ft 2 ) 
                 $17.22/Ft2 
               
               
                 Price/M 2   
                 $188/M 2   
               
               
                 Price/Watt 
                 $1.17/watt 
               
               
                   
               
             
          
         
       
     
       Solar Panel Frame  208 : 
       [0121]    For construction purposes, it is feasible to select a “solar frame” as a unit power generator to power the electrolysis cells. This frame should have a dimension easy to build, transport, installed, and have enough irradiant capture area. The frame is made from four (4) panels of “LG 265 Si C” and has dimension of 3.3 m×2.0 m with area of 6.6 m 2 .  FIG. 9  shows solar frame  208 , which is made from four (4) solar panels  209 . 
       Frame&#39;s Energy Production: 
       [0122]    The frame energy production when installed in California or Florida (with annual average of 1000 w/m 2 ) and with efficiency of 16.4% will be: 
         [0000]        Pm= 16/4%×1000 w/m2×6.6 m 2 =1082 w (frame power point)
 
         [0000]    Annual Frame&#39;s production is: 
         [0000]      KWH/year=(365 days)×(five hrs./day)×1.082 kW=1975 KWH/yr.
 
         [0000]    Frame&#39;s Life production is: 
         [0000]      KWH/yr.×25 yrs.=49,366 KWH/lifetime
 
       Solar Frame&#39;s Cost: 
       [0123]    The cost of each frame made of four (4) panels LG 265 Si C will be: 
         [0000]      4 panel×$310/panel+$260.holding frame=$1500/frame
 
       Frame&#39;s Voltage and Current: 
       [0124]    All four (4) panels each with power voltage of 31.2 v and current of 8.46 amps electrically connected in parallel. Therefore, the frame voltage is 31.2 volts and frame current is near 35 amps. 
       Frame&#39;s Energy in Column “C”: 
       [0125]    Frame energy production in Column C is dependent on operating voltage of chlorine producing cells. 
         [0126]    In membrane cell (selected for this invention), the operating voltage is 3 to 3.6 volts with average of 3.3 volts. 
         [0127]    Frame&#39;s energy in column for one (1) year and lifetime is given per the following equations: 
         [0000]    
       
      
       I=W 
       watts 
       /V 
       volts 
       =A 
       amps  
      
     
         [0000]        I= 1082 w/3.3 v=327.9 Amps 
         [0000]    
       
      
       C 
       column 
       =I 
       Amps 
       ×t 
       second  
      
     
         [0000]        C /Frame annual=(327.9 Amps)×(365 day/yr.)×(5 hrs./day)×(3600 sec/hr.)
 
         [0000]        C /Frame annual=2.154×10 9  column/year
 
         [0000]        C /Frame 25 year=5.386×10 10  column/25 yeas.
 
         [0000]        F /Frame year=2.23/10 4  Farad/year 
         [0000]        F /Frame 25 years=5.582×10 5  Farad/25 year
 
       Frame&#39;s Annual Theoretical Production: 
       [0128]    In theory, one farad of electric energy in electrolysis of one molecule gram of table salt solution will produce the following elements:
       1. Chlorine gas: one atom gram of gas that is 35.5 grams   2. Hydrogen: one atom gram hydrogen, that is 1.01 grams   3. Sodium: one atom gram Na, that is 23 grams or 40 grams of 100% causticsoda.
 
Production can be calculated as:
       
 
         [0000]    
       
         
           
             
               
 
             
              
             
               
                 
                   
                     
                       1. 
                        
                       
                           
                       
                        
                       
                         Frame 
                         ′ 
                       
                        
                       s 
                        
                       
                           
                       
                        
                       
                         Cl 
                         2 
                       
                        
                       
                         / 
                       
                        
                       year 
                     
                     = 
                       
                      
                     
                       
                         ( 
                         
                           2.23 
                           × 
                           
                             10 
                             4 
                           
                            
                           
                               
                           
                            
                           F 
                         
                         ) 
                       
                       × 
                       
                         ( 
                         
                           35.5 
                            
                           
                               
                           
                            
                           
                             Gr 
                             / 
                             
                               10 
                               6 
                             
                           
                            
                           Gr 
                            
                           
                             / 
                           
                            
                           ton 
                         
                         ) 
                       
                     
                   
                 
               
               
                 
                   
                     = 
                       
                      
                     
                       0.791 
                        
                       
                           
                       
                        
                       ton 
                        
                       
                         / 
                       
                        
                       
                         yr 
                         . 
                       
                     
                   
                 
               
             
           
         
       
       
         
           
             
               
                 
                   
                     2. 
                      
                     
                         
                     
                      
                     
                       Frame 
                       ′ 
                     
                      
                     s 
                      
                     
                         
                     
                      
                     Na 
                      
                     
                         
                     
                      
                     OH 
                      
                     
                       / 
                     
                      
                     
                       yr 
                       . 
                     
                   
                   = 
                     
                    
                   
                     
                       ( 
                       
                         2.23 
                         × 
                         
                           10 
                           4 
                         
                          
                         
                             
                         
                          
                         F 
                       
                       ) 
                     
                     × 
                     
                       ( 
                       
                         40 
                          
                         
                             
                         
                          
                         
                           Gr 
                           / 
                           
                             10 
                             6 
                           
                         
                          
                         Gr 
                          
                         
                           / 
                         
                          
                         ton 
                       
                       ) 
                     
                   
                 
               
             
             
               
                 
                   = 
                     
                    
                   
                     0.892 
                      
                     
                         
                     
                      
                     ton 
                      
                     
                       / 
                     
                      
                     
                       yr 
                       . 
                     
                   
                 
               
             
           
         
       
       
         
           
             
               
                 
                   
                     3. 
                      
                     
                         
                     
                      
                     
                       Frame 
                       ′ 
                     
                      
                     s 
                      
                     
                         
                     
                      
                     
                       H 
                       2 
                     
                      
                     
                       / 
                     
                      
                     
                       yr 
                       . 
                     
                   
                   = 
                     
                    
                   
                     
                       ( 
                       
                         2.23 
                         × 
                         
                           10 
                           4 
                         
                          
                         
                             
                         
                          
                         F 
                       
                       ) 
                     
                     × 
                     
                       ( 
                       
                         1.01 
                          
                         
                             
                         
                          
                         
                           Gr 
                           / 
                           
                             10 
                             6 
                           
                         
                          
                         
                           / 
                         
                          
                         ton 
                       
                       ) 
                     
                   
                 
               
             
             
               
                 
                   = 
                     
                    
                   
                     0.225 
                      
                     
                         
                     
                      
                     ton 
                      
                     
                       / 
                     
                      
                     
                       yr 
                       . 
                     
                   
                 
               
             
           
         
       
     
     
    
     C—DETAILED DESCRIPTION OF INVENTION 
       [0132]    The Invention is Solar Powered Chlorine Producing Module for 50 tons of chlorine per year, called “SCPM”. 
         [0133]    “SCPM” has two main parts: 
         [0000]    A—Solar panel assembly that provides power called “solar power producer”
 
B— Chlorine Producing Unit called “Cl 2  Unit”
 
       A—Solar Power Producer  215 : 
       [0134]      FIG. 9  depicts a “SCPM” (Solar Powered Chlorine Producing Module) with 50 ton Cl 2  per year. 
         [0135]    The power source of this module is the assembly  215  that is made of  64  solar frames  208 , and arranged in eight columns. Each column has eight (8) solar frames  208 . The solar frame  208  are made from four (4) commercially silicon solar panels of  209 . The solar panel is model “LG265 Si.C 265G3” product line of “Monox” that its specification is already given in the solar section. All sixty-four (64) solar frame are electrically connected in parallel according to wiring  210 , and the final power feeder  211  to “Cl 2  unit  212 ” will have voltage of 31 volts and the current of 2233 amps. 
         [0136]    Feeder  211  of  FIG. 9  could be a single copper bus strap start from the right-hand side to the left side with the following dimensions:
       1. Section C1C2 and D1D2 will have a cross-section of ⅜″×2¼″ (10 m /m×54 m /m) or 1×800 MCM, THHN wire carrying 558 amps   2. Section C2C3 and D2D3 will have a cross-section of ⅜″×5.5″ (10 m /m×75 m /m) or 2×800 MCM, THNN wire carrying 1116 amps   3. Section C3C4 and D3D4 will have a cross-section of ¾×3½″ (20 m /m×80 m /m) or 3×800 MCM, THNN wire carrying 1675 amps   4. Finally, Section C4C5 and D4D5 and throughout of “Cl 2  unit” will have a cross-section of ¾×4½″ (20 m /m×110 m /m) or 4×800 MCM, THNN wire carrying 2233 amps       
 
         [0141]    “Cl 2  Unit  212 ” Electrical Connection  211 : 
         [0142]      FIG. 10  depicts the power supply  211  to “Cl 2  unit  212 ”. The “Cl 2  unit  212 ”. Has nine (9) membrane cells  214 , each operating with 3.3 volts and 2233 amps. Membrane cells are electrically connected in series connection  213 . 
       Specification of Solar Power Assembly  215 : 
       [0143]      
         [0000]    
       
         
               
               
               
             
               
               
             
               
               
               
             
           
               
                   
               
             
             
               
                 Solar Irradiance 
                 1000 
                 Watts/m2 
               
             
          
           
               
                 Solar Panel 209 model 
                 LG 265 SIC 265 G3″ 
               
               
                 Manufacturer 
                 Monox 
               
               
                 Solar Panel 209, dimension 
                 165 Cn × 100 Cn × 3.5 Cn 
               
               
                 Solar Frame 208 dimension 
                 330 Cn × 200 Cn × 3.5 Cn 
               
               
                 No. of Panel 209 in frame 208 
                 2 × 2 panels (4 panels) 
               
             
          
           
               
                 Frame 208 Pmax 
                 1082 
                 watts 
               
               
                 Frame 208 V Max   
                 31.4 
                 volts 
               
               
                 Frame 208 I SC Max   
                 34.9 
                 amps 
               
               
                 No. of Frame 208 in solar assembly 
                 64 
                 frames 
               
               
                 Solar power 215 operating voltage 
                 31 
                 volts 
               
               
                 Solar power 215 operating current 
                 2233 
                 amps 
               
               
                 Solar power 215 capture area 
                 422 
                 M 2   
               
               
                   
               
             
          
         
       
     
       B—Chlorine Producing Unit “Cl 2  Unit”  212   
       [0144]      FIGS. 11 -A,  11 -B and  11 -C depict frontal view, side view, and cross-sectional view of new membrane chlorine producing Unit  212  in  FIG. 9 , that will be used in this invention.  FIG. 11 -A depicts the arrangement of a row of nine (9) cells  108 , piping connection of entering saturated Brine  100  and leaving depleted Brine  116 , diluted Caustic  121  and 33% Caustic  113  leaving the Unit.  FIG. 11 -B depicts the structural Frame  114  to support the two rows of membrane Cells  108 , saturated Brine  100  and its branches to Cells  108 , diluted Caustic  121 , and pure Water  112  and its branches to diluted Caustic  121 .  FIG. 11 -C depicts the cross-section of one cell with its related piping. Brine Container  108  is a PVC slim cylinder, a non-permeable ion-exchanger Membrane  107  divided the Container  108  into Anode Chamber  109  and Cathode Chamber  110 . Saturated Brine  100  enters Anode Chamber  109  and depleted Brine  116  leaves the Anode Chamber  109  at the top. Pure Water  112 , along with diluted Caustic  121 , enters at the bottom of Cathode Chamber  110  and 33% Caustic Soda  113  leaves Cathode Chamber  110  at the top. Chlorine Gas  104  leaves the Anode Chamber  109  at the top, and Hydrogen Gas  105  leaves at the top of Cathode Chamber  110 . 
       Anode  101 : 
       [0145]    Up to 1970 electrolytic cell, anodes were graphite. New anodes are Titanium (Ti) metal electro-coated with an Oxide of Platinum group family (Ruthenium, Titanium, Tin and zirconium). Titanium anode Electro-Coated with Ruthenium Oxide (RUO 2 ) and Titanium oxide (TiO 2 ) are high current density in low voltage. The use of RUO 2  and TiO 2  coated Titanium Anodes reduces energy consumption by about 10% and higher life expectancy. Competitive design of anode geometry is today&#39;s industry challenge, all with the aim of improving gas release, to reduce Ohmic resistance losses and increase the anode life by improving the homogeneity of the brine. 
       Life of Anode: 
       [0146]    Metal Anode lives are 12, 8 and 4 years for diaphragm, membrane, and mercury, respectively. In mercury cell, short circuit between anode and cathode cause the wear of anode coating. 
       Cathode  102 : 
       [0147]    Is nickel often coated to reduce energy consumption? Reducing the distance between Anode  101  and Cathode  102  will reduce the ohmic resistance and Will reduces the operating voltage and energy. This is the reason behind the new slim cylinder cells. 
         [0148]    Recently, a new oxygen depolarized cathode (ODC) has been used. Oxygen is pumped into the cell to react with liberated hydrogen in Cathode to form water, results in lower cell resistance, and lower the voltage needed for the electrolysis process. This voltage reduction could be as low as 50%. A disadvantage of this process is that the hydrogen is no longer available as an important and valuable product. 
       Membrane  107 : 
       [0149]    Membrane  107  with thickness 0.15 to 0.3 mm is co-polymer of tetra-fluoroethylene (C 2 .F 4 ) Groups, and is non-permeable, but ion exchanger membrane. 
       Maintenance and Operation: 
       [0150]    To reduce the maintenance cost of cell operation, the following precautions should be considered:
       1—Organic acids, Fluorides and Manganese cause damage to anode&#39;s Coating.   2—Operation in alkaline brine with PH bigger than eleven (PH&gt;11) will cause a rapid destruction of the Anode&#39;s coating   3—Operation with low concentrated and cold brine led to production of Sodium Hippo Chloride (Cl O Na) that should be avoided.       
 
       Membrane Cell Consumption and Productions: 
       [0000]    
       
         
           
             The following numbers are the, products, material and energy used, as base, to produce one metric ton (1000 kg) of chlorine gas: 
             a—One metric ton of chlorine gas. 
             b—Other Products;
           b 1 —1.128 tons of 100% Na OH (Sodium hydroxide).   
         
             or b 2 —Alternatively, 1.577 tons of 100% KOH (Potassium hydroxide).
           c—By product of 28 Kg hydrogen.   
         
             d—Raw material;
           d 1 —1.66 tons of pure table salt (Cl Na).   
         
             or d 2 —2.1 to 2.2 tons of potassium chloride (Cl K). 
             e—Energy used;
           e 1 —To-day&#39;s Membrane Cells use 2,500 KWH per one metric ton of chlorine.   e 2 —Extra 500 KWH will used to concentrate the caustic soda to 50%.   
         
           
         
       
     
       Product&#39;s Purification and Concentration: 
     Chlorine Purification; 
       [0166]    Chlorine produced by all cells has some water vapor. Concentrated sulfuric acid (92% to 98% of So 4 H2) is used to dry chlorine. If re-concentration takes place at site, also a small amount of the sulfuric acid per ton of chlorine will be used for elimination of (Cl—O—Na) and PH control. 
         [0167]    Caustic soda produced by cells has some Cl Na, by boiling the product; excess salt will be crystallized and separate from caustic soda. 
       Caustic Soda Concentration; 
       [0168]    Indirect heating with steam will do caustic soda concentration, and sulfuric acid concentration. 
       Specification of Designed “Cl 2  Unit  212 ” 
       [0169]      
         [0000]    
       
         
               
               
               
             
               
               
             
               
               
             
               
               
               
               
             
               
               
             
               
               
               
               
             
               
             
               
               
               
               
             
               
               
               
             
               
               
               
               
             
               
               
               
             
               
               
               
             
               
             
               
               
               
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                   
               
             
             
               
                 1 - Unit capacity 
                 50 
                 ton/year 
               
             
          
           
               
                 2 - Number of membrane cells 
                 nine cells 
               
               
                 3 - Power supply: 
                 solar 
               
             
          
           
               
                   
                 a - Operating Voltage V op   
               
             
          
           
               
                   
                 a-1 -V op Max  (Noon time) 
                 34 
                 volts 
               
               
                   
                 a-2 -V opMin  (Morning &amp; Afternoon) 
                 3.4 
                 volts 
               
             
          
           
               
                   
                 b - Operating current I op   
               
             
          
           
               
                   
                  b-1- I op Max  (Noon time) 
                 2233 
                 AMPS 
               
               
                   
                  b-2 -  Iop Min  (Morning &amp; Afternoon) 
                 700 
                 AMPS 
               
             
          
           
               
                 4 - Membrane: 
               
             
          
           
               
                   
                 a - current density “design” KA/Ft 2   
                 450 
                 AMPs/Ft 2   
               
             
          
           
               
                   
                 4.84 
                 Kamp&#39;s/M 2   
               
             
          
           
               
                   
                 b - Area/cell 
                 5 
                 Ft 2 /cell 
               
               
                   
                 c - Membrane Diameter 
                 4 
                 inches 
               
               
                   
                 d - Membrane length 
                 60 
                 inches 
               
               
                   
                 e - Membrane Area/cell “actual” 
                 5.23 
                 Ft 2 /cell 
               
               
                   
                 f - Current Density “actual” 
                 426.7 
                 AMPS/Ft 2   
               
             
          
           
               
                   
                 4.59 
                 Kamp&#39;s/M 2   
               
             
          
           
               
                   
                 g - “Cl 2  Unit” total area (9 × 5.23 M 2 ) 
                 47 Ft 2  (4.37 M 2 ) 
               
             
          
           
               
                 5 - Production per year: 
               
             
          
           
               
                   
                 a - Chlorine gas (metric ton = 1000 Kg) 
                 50 
                 ton/year 
               
               
                   
                 b - Caustic Soda 
               
             
          
           
               
                   
                  100% 
                 56.4 
                 ton/year 
               
               
                   
                   50% 
                 112.8 
                 ton/year 
               
             
          
           
               
                   
                 c - Hydrogen 
                 1.4 
                 ton/year 
               
               
                   
                   
               
             
          
         
       
     
       Case Study: 
       [0170]    This invention was applied in design of chlorine producing plant for a municipality with a population of 170,000. 
         [0171]    In this design, the production capacity could be increased throughout the life of the plant if chlorine demand increases. In the 25-year life of the plant, there will be four times capacity expansion at the start of the 2 nd , 3 rd , 4 th  and 5 th  period of five years period with addition of 3, 3, 4, and 3 “SCPM, 50 ton/yr.” to the plant. Due to this expansion, the increase of Cl 2  production takes place in four (4) steps, while the city demand is exponential; that results in excess Cl 2  production. 
         [0172]    The excess chlorine will be sold to other cities at 80% of the buying price of offsite Chlorine by city, as an income to the city. 
         [0173]    The city&#39;s caustic soda consumption is about 33% of the plant production. The 67% excess product of the plant will be sold to other cities at 75% of the buying price of offsite caustic soda by city, as an income to the city. 
         [0174]    The plant hydrogen by-product may be sold at the price of 75% of the market price as income to the city. 
         [0175]    If, instead of selling the hydrogen, it is converted to ammonia (NH 3 ), it will provide 56.5% of City&#39;s consumption, and the city needs to buy only 43.5% of its consumption. 
         [0176]    The summary of this case study has been given in the following graphs.
         FIG. 12 —depicts the City&#39;s population from 2008 to 2040 according to the U.S. Census Bureau     FIG. 13 —depicts the City&#39;s chlorine (2015-2040):
           a. Annual chlorine consumption   b. Annual suggested plant production   
             FIG. 14 —depicts the City&#39;s caustic soda (2015-2040):
           a. Annual caustic soda (Na OH) consumption   b. Annual suggested plant production   
             FIG. 15 —depicts the City&#39;s ammonia (2015-2040):
           a, Annual ammonia “NH 3 ” consumption.   b, Annual ammonia “NH 3 ” production   
             FIG. 16 —depicts: The city&#39;s cost for chlorine and caustic (2015-2040):
           a. Annual cost of chlorine consumed   b. Annual cost of caustic soda consumed   c. Total City&#39;s annual cost of Cl 2  plus caustic soda.   
             FIG. 17 —depicts the initial required number of “SCPM” modules in the plant, and the number of “SCPM” modules in the plant&#39;s expansion to meet the City&#39;s chlorine demand.     FIG. 18 —depicts the City&#39;s hydrogen (H 2 ) product as the plant&#39;s by-Product.     FIG. 19 —depicts:
           a. City&#39;s income by selling hydrogen at 75% of market price.   b. City&#39;s income if all hydrogen converted to ammonia (NH 3 ) as supply near of 57% of City&#39;s ammonia consumption.   
             FIG. 20 —depicts:
           a. The cost of solar power  215  per module “SCPM”,  FIG. 9 .   b. The cost of “Cl 2  unit  212 ” per module “SCPM”,  FIG. 9 .   
             FIG. 21 —depicts:
           Accumulated plant capital cost in 25 years period.   
             FIG. 22 —depicts the plant&#39;s total running cost in 25 years.     FIG. 23 —depicts
           a, Employees wage to operate the plan through its life span of 25 years.   b, the cost of annual Table Salt consumed as raw material for 25 years plant&#39;s life span.   
             FIG. 24  depicts—
           a, plant&#39;s total income per 5-years period.   b, Accumulated plants total cost in 25 years.   c, Accumulated plants total income in 25 years.   
           At year 2040 (the end of plant&#39;s life)
           the total accumulated income in 25 years is about $76,300,000.   the total accumulated cost including capital investment and running cost (Running energy+Maintenance+Replacement) in 25 years is About $33,560,000.   The plant&#39;s net income in 25 years is $42,740,000.   
               
 
       BRIEF DESCRIPTION OF DRAWINGS 
       [0213]    To explain and better understanding of drawings, assigned numbers has identified the products, elements of solar power producing unit, chlorine producing cell assembly, and related accessories. The assigned numbers used in figures are given in the following table. 
       DESCRIPTION OF ASSIGNED NUMBERS 
       [0214]      
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
               
               
                   
                   
                 ASSIGNED 
               
               
                 ITEM 
                 DESCRIPTION 
                 NUMBERS 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 Electrolyte Solution: 
                 100 
               
               
                   
                 Acid + Water/Salt + Water 
               
               
                 2 
                 Anode 
                 101 
               
               
                 3 
                 Cathode 
                 102 
               
               
                 4 
                 DC Power Source 
                 103 
               
               
                 5 
                 Anion (Non-metallic elements) 
                 104 
               
               
                   
                 Cl 2 , O 2   
               
               
                 6 
                 Cation (Metallic elements) Na, Fe, H 
                 105 
               
               
                 7 
                 Caustic Soda under 30% 
                 106 
               
               
                 8 
                 Diaphragm or Membrane 
                 107 
               
               
                 9 
                 Cell Container 
                 108 
               
               
                 10 
                 Anode Chamber 
                 109 
               
               
                 11 
                 Cathode Chamber 
                 110 
               
               
                 12 
                 Diluted Brine 
                 111 
               
               
                 13 
                 Pure Water 
                 112 
               
               
                 14 
                 Caustic Soda 33% 
                 113 
               
               
                 15 
                 Structural Frame 
                 114 
               
               
                 16 
                 Brine Concentrator 
                 115 
               
               
                 17 
                 Depleted Brine 
                 116 
               
               
                 18 
                 Decomposer 
                 117 
               
               
                 19 
                 Amalgam (Na Hg) 
                 118 
               
               
                 20 
                 Recycled Mercury 
                 119 
               
               
                 21 
                 Caustic Filter 
                 120 
               
               
                 22 
                 Diluted Caustic Soda 
                 121 
               
               
                 23 
                 Solar Panel at 32° 
                 200 
               
               
                 24 
                 Solar Panel at Noon 
                 201 
               
               
                 25 
                 Solar Panel at 6:00 a.m. &amp; 6:00 p.m. 
                 202 
               
               
                 26 
                 Sun at 6:00 a.m. &amp; 6:00 p.m. 
                 203 
               
               
                 27 
                 Sun at Noon 
                 204 
               
               
                 28 
                 Sunlight at Noon 
                 205 
               
               
                 29 
                 Sunlight at 6:00 a.m. &amp; 6:00 p.m. 
                 206 
               
               
                 30 
                 Horizon 
                 207 
               
               
                 31 
                 Solar Frame 
                 208 
               
               
                 32 
                 Solar Panel 
                 209 
               
               
                 33 
                 Parallel Connection 
                 210 
               
               
                 34 
                 Power to Cl 2  Producing Unit 
                 211 
               
               
                 35 
                 Cl 2  Producing Assembly Unit 
                 212 
               
               
                 36 
                 Series Connection 
                 213 
               
               
                 37 
                 “SCPM” Membrane Cl 2  Cell 
                 214 
               
               
                 38 
                 Solar Power Producing Unit Assembly 
                 215 
               
               
                   
               
             
          
         
       
     
         [0215]      FIG. 1  shows the basic set-up in the laboratory. It explains electrolysis of water with hydrochloric water  100  or solution of Table Salt  100  into their elements. Water  100  breaks down into Oxygen  104  in Anode  101  and Hydrogen  105  in Cathode  102 . Table sale Solution  100  breaks down into Chlorine  104  in Anode  101  and Na OH  106  in Cathode  102 . 
         [0216]      FIG. 2  explains the concept of diaphragm cell for producing chlorine from saturated table salt solution. Diaphragm  107  divides Container  108  into two sections of Anode Chamber  109  and Cathode Chamber  110 . Saturated Brine  100  enters Anode Chamber  109  at the top. Chlorine ions will be attracted to anode  101 , give up one electron, and become chlorine Gas  104  that accumulates at the top of Anode Chamber  109 . Sodium ions pass through Diaphragm  107  and enter Cathode Chamber  110 . Some interact with Hydroxide Ions (OH −1 ) from Cathode  102  to form Caustic Soda  106 , while some attract to Cathode  102 , receive one electron and convert to metallic sodium. Metallic sodium reacts with water to produce Caustic Soda  106  and Hydrogen  105  which accumulates at the top of Cathode Chamber  110 . 
         [0217]      FIG. 3 , is a view of commercial diaphragm cell. In this Figure, Brine  100 , Anode  101 , Cathode  102 , Power  103 , Chlorine Gas  104 , Hydrogen Gas  105 , diluted Caustic Soda  106 , Diaphragm  107 , Container  108 , Anode Chamber  109 , Cathode Chamber  110 , Diluted Brine  111 , and 30% Caustic Soda  113  are given. Diluted Brine  111  passes through diaphragm  107  into Cathode Chamber  110 . 
         [0218]      FIG. 4 , is a simplified view of a membrane chlorine producing cell. A non-permeable and ion-exchanger membrane  107  divides the Container  108  into two Anodes, Chamber  109  and Cathode Chamber  110 . Saturated Brine  100  enters from the bottom to Anode Chamber  109  and as depleted brine  116  leaves the Chamber  109  at the top. Caustic Soda  106  and Water  112  enter the Cathode Chamber  110  at the bottom and as it moves up, it picks Caustic Soda generated in Cathode  102 . Rich Caustic Soda  113  with 30% to 33% density leaves at the top. Chlorine Gas  104  accumulates at the top of Anode  101  and Hydrogen Gas  105  collects at the top of Cathode  102 . 
         [0219]      FIG. 5 , shows a view of commercial chlorine membrane cell. All elements in this drawing is the same as  FIG. 4  except that the brine circuit from saturated 100% entering the Anode Chamber  109 , loses its chlorine ions to Anode and becomes depleted Brine  116  that enters into concentrator  115 , becomes saturated Brine  100  and repeats the cycle. Caustic Soda 33% of  113  enters to caustic container and leaves the cell. Caustic soda  106  as Part of Caustic Soda  113  becomes diluted with Water  112 , enters to Cathode Chamber  110 , receives caustic from Cathode  102  and becomes 33% Caustic  113 . Ions of Na +1  Enter Cathode Chamber  110 , some interact with Hydroxide ions (OH −1 ) from Cathode  102  to from Caustic Soda  106 , and some attract to Cathode  102 , receive one electron and convert to metallic Sodium. Metallic Sodium reacts with water to produce caustic soda  106  and Hydrogen  105 , which accumulates at the top of Cathode Chamber  110 . 
         [0220]      FIG. 6 , shows a simplified view of Chlorine Mercury Cell. A mercury film over an inclined flat surface acts as Cathode  102 . Anode  101  is metal plates parallel to mercury surface and in close distance. Saturated Brine  100  enters the Container  108  from the top. It gives away its chlorine ions to Anodes  101  that become Chlorine Gas  104 . Its sodium ions go to mercury Cathode  102  and by receiving one electron become Metallic Sodium. Sodium reacts with mercury and forms Amalgam (Na—Hg  118 ) that leaves Cathode  102 . After all this process, saturated Brine  100  becomes depleted Brine  116  that leaves the cell at the top. Amalgam (Na—Hg  118 ) in Decomposer  117  reacts with Water  112 , breaks down into Caustic Soda 50%  113  and Hydrogen  105  and recycled Mercury  119 . Hydrogen  105  will be collected at the top of the Decomposer  117  and Mercury  119  will be pumped to Cathode  102 . 
         [0221]      FIG. 7 , Shows a view of commercial mercury chlorine cell. All elements and process are identical to  FIG. 6 . 
         [0222]      FIG. 8 , Shows a rotating solar Panel  200 . Panel orientation at Noon  201  has a tilted angle of 42°, and panel Position  202  has better efficiency at early morning and afternoon. The sun&#39;s location is given at Noon  204  and for early morning and late Afternoon  203 , having angles of 42° and 32° respectively with horizon  207   
         [0223]      FIG. 9 , Shows Solar Power Producer  215 , part of invention of “SCPM” (Solar Powered Chlorine Producing Module). Solar power Producer  215  is made of eight columns and each column has eight Frames ( 208 ), with the sixty-four (64) frames. Each Frame  208  has four solar panels of  209 . In this assembly, all panels are connected electrically in Parallel  210  and the power to chlorine cells  211  has 30 v and 2233 amps. 
         [0224]      FIG. 10 , Shows Membrane Cells  214  is electrically connected in Series  213 . Power feeds to Assembly  211  has 30 v and 2233 amps. 
         [0225]      FIG. 11 -A, Shows front view of “SCPM”-“Chlorine Producing Cell” assembly and its associated piping. The Assembly has nine (9) membranes Cells  108 . The cell&#39;s detail is given in  FIG. 11( c ) . Saturated Brine  100  enters Anode Chamber  109  cells from the bottom strip off its ions, moves up and leaves the cell as depleted Brine  116 . Diluted Caustic Soda  121  mixes with pure Water  112  and enters at the bottom of Cathode Chamber  110 . As it moves up, it receives Caustic Soda (Na OH) from Cathode  102 , becomes rich Caustic  113  with 33% that leaves the Assembly at the top. 
         [0226]      FIG. 11 -B, Shows the side view of “SCPM”-Solar Chlorine Producing Module. The view shows two membrane Cells  108  and associated piping. The main saturated Brine  100  and its branch feed to each cell located at the bottom. Diluted Caustic Soda  121  and pure Water  112  and their associated piping are located at the bottom of the cell. Structural metal Frame  114  supports cells and associated pipes. Caustic Soda 33% collector Pipe  113  and its branches to cell&#39;s cathode chamber are located at the top. Hydrogen collector Pipe  105  and its branches to cathode chamber are located at the top of the cell. Depleted brine collector pipe  116  and chlorine collector Pipe  104  and their branches to cell&#39;s anode camber are located at the top of the Assembly. 
         [0227]      FIG. 11 -C: Shows the cross section of membrane cell. Brine Container  108  is divided by cylindrical non-permeable and ion exchanger Membrane  107  into Anode Chamber  109  and Cathode Chamber  110 . Saturated Brine  100  enters Anode Chamber  109  at the bottom, gives up its ions as it moves up and becomes depleted Brine  116  that leaves the cell a t the top. Chlorine Gas  104  releases from Anode  101 , will be collected at the top of Anode Chamber  109 , and leaves the cell. Diluted Caustic  121  mixes with pure Water  112  and enters Cathode Chamber  110  at the bottom. As it moves, up, it absorbs caustic soda from Cathode  102  and becomes Caustic Soda  113  with 33% that leaves the cell at the top. Hydrogen Gas  105  that release from Cathode  102  will be collected at the top of Cathode Chamber  110  and leaves the cell. 
       Case Study&#39;s Figures 
       [0228]      FIG. 12 , The City&#39;s population from Year 2000 to Year 2040 
         [0229]      FIG. 13 , The City&#39;s chlorine consumption (2000-2040) and chlorine produced by “SCPM” Plant from Year 2015 to 2040 
         [0230]      FIG. 14 , The City&#39;s caustic soda (Na OH) consumption and caustic soda produced by “SCPM” plant from year 2015 to 2040 
         [0231]      FIG. 15 , The City&#39;s ammonia (NH 3 ) consumption and “SCPM” ammonia production from Year 2015 to 2040. 
         [0232]      FIG. 16 , The City&#39;s cost for used chlorine (Cl 2 ) and caustic soda (Na OH) and their total from year 2015 to 2040 
         [0233]      FIG. 17 , The City&#39;s plant required number of “SCPM” (module with 50-ton chlorine Production per year) from Year 2015 to 2040. 
         [0234]      FIG. 18 , The City&#39;s hydrogen production, by city chlorine plant from Year 2015 to 2040. 
         [0235]      FIG. 19 , The City&#39;s income if hydrogen is marketed directly, or converted to ammonia From Year 2015 to 2040. 
         [0236]      FIG. 20 , The cost of one solar power assembly  215 , ( FIG. 9 ) and one chlorine cell assembly  212 , ( FIG. 9 ) of one “SCPM” from Year 2015 to 2040. 
         [0237]      FIG. 21 , The City&#39;s initial capital cost in Year 2015 and additional capital cost for the Plant&#39;s capacity increase for four periods of five years, from 2015 to 2040. 
         [0238]      FIG. 22 , The Plant&#39;s total running cost from Year 2015 to 2040, and two major chlorine cells replacement in Years 2025 and 2035. 
         [0239]      FIG. 23 , The City&#39;s chlorine plant cost of raw material and labor,
       a—the plant&#39;s cost of employees that run the plant from Year 2015 to 2040.   b—the plant&#39;s cost of used table salt from Year 2015 to 2040.         
         [0242]      FIG. 24 , Shows the, capital cost, running cost, and income from 2015 to 2040.
       a—plant&#39;s total gross income per five-year period for 2015 to 2040   b—plant&#39;s accumulated cost (capital and running cost) from Year 2015 to 2040.   c—plant&#39;s accumulated gross income from Year 2015 to 2040   d—Shaded area is accumulated net income at any time of plant&#39;s life. At 2040 (end life), the accumulated net income well be $42,740,000.—At end of the plant&#39;s life.