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Elements of a Chemical Dosing System | Pumps, Tanks & Controls

April 30, 2025 Welcome

Chemical dosing systems help move chemicals into a process-automatically, accurately, and on schedule. They’re used everywhere from water treatment to industrial manufacturing. The ultimate goal is to keep things consistent and safe. Now, let’s explore the main pieces: pumps, tanks, and controls.

Basics of Chemical Dosing

Chemical dosing means putting a chemical into a system in a set amount. Not too much, not too little. It could be to balance pH, disinfect, or start a reaction. You’ll see it in plants that clean water, in HVAC setups, even food production lines. The job is to get the mix right, every time.

Common Chemicals Used:

Sodium hypochlorite
Sulfuric acid
Ferric chloride
Polymers and coagulants
Hydrochloric acid
Sodium hydroxide

Applications:

Municipal water and wastewater treatment
HVAC and cooling systems
Pulp and paper manufacturing
Food and beverage sanitation

Chemical Dosing Pumps

Selecting the right pump is a foundational step in any chemical dosing setup. Pumps serve as the delivery mechanism, determining how accurately and consistently chemicals are introduced into the process stream. Therefore, the type of pump used will impact reliability, precision, and compatibility with the chosen chemical.

Types of Dosing Pumps

The selection of a dosing pump depends heavily on the fluid properties, required accuracy, and system conditions. Common types include:

Diaphragm Pumps (Mechanical & Hydraulic): Suitable for corrosive or viscous fluids.
Peristaltic Pumps: Preferred for shear-sensitive chemicals and fluids with particulate.
Piston Pumps: Best for high-pressure systems requiring precise metering.
Solenoid-Driven Pumps: Compact, energy-efficient, and designed for low-flow dosing.

Pump Selection Criteria

Not every pump fits every job. Start with how fast and how hard the chemical needs to move – flow rate and pressure. Then think about what’s in the chemical. Is it harsh? Thick? Solids? That decides what the pump’s made of. Some setups run nonstop. Others need a quick dose here and there. Match the pump to how the system runs, not the other way around.

Here are some installation and maintenance best practices:

Position the pump close to the tank to minimize suction head
Use flexible connections to reduce vibration
Calibrate regularly using a graduated cylinder or calibration column

Maintenance should also include routine checks for leaks, worn diaphragms, and suction line clogs. Periodic flushing and part replacement can extend the system’s lifespan significantly.

Chemical Storage Tanks

After selecting a suitable pump, the next consideration is how and where chemicals will be stored. Storage tanks play a direct role in dosing efficiency and long-term chemical stability (and safety). The sections below review tank materials, sizing, placement, and how tanks interact with the rest of the system.

Tank Materials and Chemical Compatibility

Chemical storage tanks must be constructed from materials compatible with the chemical being stored:

Polyethylene/Polypropylene: Common for acids and caustics
FRP (Fiberglass-Reinforced Plastic): Resistant to a wide range of chemicals
Stainless Steel: Used for high-temperature or aggressive environments

Tank Sizing and Placement

Tanks should be sized for at least 2-3 days of chemical demand, considering delivery schedules and process changes. Placement is equally important. Tanks must be easy to access for filling and inspection, well-supported to carry their full weight, and located in ventilated areas if the contents are volatile.

In regions with extreme temperatures or exposure to sunlight, tanks may require insulation or shielding to protect chemical stability.

Integration with Dosing Pumps

Pumps don’t work well without the right setup at the tank. You want clean and steady suction, so you’ll need foot valves, strainers, and some way to handle backpressure. If the chemical settles or separates, keep it moving with a mixer or loop. It’s not about fancy gear. It’s about keeping things steady, so nothing clogs or doses off-target.

Control Systems and Instrumentation

Types of Control Panels

From manual control to advanced automation:

Timer-Based Systems batch dosing and basic repeat cycles
PLC/SCADA Systems enable real-time control, historical data tracking, and integration with larger plant control systems

Sensors and Feedback Loops

Sensors provide direct feedback for process control:

Flow Meters confirm correct delivery volume
pH/ORP Sensors adjust dosing to maintain setpoints
Level Sensors prevent pump damage due to dry run conditions

Automation and Remote Monitoring

Modern systems use smart tech. You can check it from your phone, get alerts when something’s off, and even fix some problems without being on-site. Some systems track wear so you can do maintenance before things break. You’re not flying blind anymore…it’s all right there, in the data.

Safety, Compliance, and Environmental Considerations

Chemical dosing systems must meet local and national regulations:

Storage Regulations: OSHA and EPA requirements for hazardous materials
Spill Containment: Double-walled tanks or secondary containment berms
Training & PPE: Staff must be trained on chemical handling and emergency response, and equipped with appropriate personal protective equipment

Proper documentation and Material Safety Data Sheets (MSDS) should be easily accessible, and systems should feature fail-safes such as emergency shut-offs and leak detection.

System Design Considerations

Designing a chemical dosing system involves balancing cost, complexity, and reliability:

Map out the full dosing process, from storage to point of chemical injection
Choose modular components for easier upgrades
Conduct site surveys to avoid installation challenges
Account for redundancy and future scalability

A well-structured system minimizes chemical waste, delivers consistent output, and simplifies ongoing maintenance.

Learn More From the Experts

DXP/IFS specializes in custom chemical dosing solutions for municipal, industrial, and commercial applications. With decades of experience in fluid handling, our engineers can help you select, design, and install a system suited to your process needs.Contact IFS today to schedule a consultation or request a custom quote.