Project Background
A customer required a customized electrolytic cell for a salt chlorination system serving a 120 m³ swimming pool. The target chlorine generation capacity was approximately 50 g/h, with a working current of 5 A and salt concentration controlled between 2,700 and 3,400 ppm. The system also required polarity reversal every 4–6 hours to help reduce mineral deposits on the electrode surface. Because the cell had to fit an existing circulation system, the customer specified a pipe inner diameter of approximately 50 mm. Rather than selecting a standard chlorine generator based only on output, the engineering team evaluated the complete operating conditions, including electrode area, current density, water flow, salt concentration, cell dimensions, and installation requirements. This approach helped define a practical cell configuration while keeping the electrode and housing compatible with the customer's existing equipment and intended operating conditions. The goal was to balance chlorine production, electrode durability, hydraulic compatibility, and practical installation within one solution.
| Specification | Value | Design impact |
| Pool volume | 120 m³ | Sets the total chlorine demand and the operating duty the cell must sustain. |
| Target output | ~50 g/h |
Drives the required active electrode area for the given working current. |
| Working current | 5 A | Governs current density and, with it, electrochemical stability and coating life. |
| Pool salinity | 2,700–3,400 ppm | A relatively low-salt window that affects cell voltage, efficiency and electrode sizing. |
| Pipe inner diameter | Ø~50 mm | Limits electrode geometry, spacing and the available water passage inside the housing. |
| Polarity reversal (Scale control) | Every 4–6 h | Periodic reversal helps manage mineral deposits on the electrode surface during repeated chlorination cycles. |
Titanium Anode Configuration
Chloride oxidation takes place at the anode surface, so the electrode - not just the cell - had to be specified for this reaction and operating environment.
Specified for the reaction, sized for the current
An MMO-coated titanium electrode was considered as the working anode, with the coating system selected according to the intended electrochemical reaction and operating environment.
Electrode geometry was sized against the 5 A working current so that effective surface area and current density were treated together. Spacing was arranged to keep an appropriate water passage while maintaining effective electrochemical contact - all within the limited internal space of the customized housing.
NAVI Titanium treats the anode, cell dimensions, electrical connections and water flow path as one integrated system: chemically suitable, and practical for assembly and continuous operation.
MMO-coated titanium
Titanium substrate with a mixed-metal-oxide catalytic coating selected for chloride oxidation in salt water.
Geometry vs. current density
Active area sized against 5 A to stay inside the coating's working window for stability and life.
Electrode spacing
Keeps the water passage open while preserving effective electrochemical contact between electrodes.
Integrated fit
Electrode, electrical connections and flow path sized together for the limited internal bore.
Electrolytic Cell Design
The electrolytic cell design required more than simply installing a pair of electrodes inside a pipe. The housing, electrode arrangement, water passage, electrical connections, sealing interfaces, and installation dimensions all needed to work together. Because the customer's pipe inner diameter was approximately 50 mm, the available internal space placed clear limits on electrode geometry and spacing. The cell configuration therefore had to provide sufficient active electrode area while maintaining a suitable flow path through the reaction zone. The engineering team also considered how the cell could be connected to the customer's existing circulation system without creating unnecessary installation difficulties. Polarity reversal was included as part of the operating concept, supporting easier management of deposits during repeated chlorination cycles. By coordinating the mechanical and electrochemical requirements at the design stage, NAVI Titanium can develop a customized cell structure that is easier to integrate, manufacture, and evaluate before moving toward larger-scale production for the customer's equipment.
Prototype and Manufacturing
Substrate selection
Titanium grade, dimensions and surface condition are defined and controlled before any coating is applied.
MMO coating
The catalytic coating system is matched to the intended electrochemical reaction and operating environment.
Electrode processing
Machining, final dimensions and configuration are checked against the drawing before the electrode moves on.
Cell assembly
Electrode positioning, electrical connections and sealing areas are verified, together with housing compatibility.
Technical evaluation
The prototype is evaluated against the confirmed operating parameters to validate the configuration.
Production
Production quantities are confirmed only after prototype validation - reducing redesign risk later on.
A staged route is particularly useful for customized salt chlorination equipment: a standard electrode may not match the required installation space or electrical conditions. Prototype evaluation confirms the configuration before production quantities are committed.
Engineering Result
Here, a 120 m³ pool, ~50 g/h chlorine output, 5 A working current, 2,700–3,400 ppm salinity, a 50 mm installation envelope and 4–6 hour polarity reversal each shaped the electrode configuration and the cell. By evaluating the electrical, electrochemical, hydraulic and mechanical requirements together, NAVI Titanium developed a solution built around the customer's existing equipment - instead of forcing the application to fit a standard product.
Fit, not force
Designed around the customer's equipment and operating conditions rather than forcing the application into a standard product.
Output + durability
Chlorine production, current density and coating life balanced in a single configuration.
Output + durability
Chlorine production, current density and coating life balanced in a single configuration.
End-to-end path
From initial technical assessment through design, testing and production - one engineering route.
