The chloralkali process is an industrial method for the electrolysis of sodium chloride (NaCl) solution, known as brine. It is the primary source for producing chlorine (Cl₂), sodium hydroxide (NaOH), and hydrogen (H₂), which are essential commodity chemicals. Modern methods use a membrane cell to separate the anode and cathode products, ensuring high purity and efficiency.
Chloralkali Process
The chloralkali process is one of the largest-scale applications of electrolysis, fundamental to the modern chemical industry. The overall reaction is \(2NaCl + 2H_2O \rightarrow 2NaOH + Cl_2 + H_2\). The process takes place in an electrolytic cell with a brine solution as the electrolyte. At the anode, chloride ions are oxidized to form chlorine gas: \(2Cl^- \rightarrow Cl_2 + 2e^-\). At the cathode, water is reduced to form hydrogen gas and hydroxide ions: \(2H_2O + 2e^- \rightarrow H_2 + 2OH^-\).
A critical aspect of the process is keeping the products, chlorine and sodium hydroxide, separate, as they would otherwise react to form sodium hypochlorite and chlorate. Historically, this was achieved using mercury cells or diaphragm cells, but these have been largely phased out due to environmental concerns (mercury pollution) and lower efficiency. The modern standard is the membrane cell. This cell uses a cation-exchange membrane (typically made of a perfluorinated polymer like Nafion) that separates the anode and cathode compartments. The membrane is permeable to positive ions like Na⁺ but impermeable to negative ions like Cl⁻ and OH⁻. Sodium ions migrate across the membrane from the anode compartment to the cathode compartment, where they combine with the hydroxide ions produced at the cathode to form high-purity sodium hydroxide.
This technology significantly improved the energy efficiency and product purity of the chloralkali process while eliminating the environmental hazards associated with mercury. The co-production of three major chemicals makes the economics of the process complex, as the market demand for chlorine and caustic soda (NaOH) must be balanced.
Type
Disruption
Usage
Precursors
- humphry davy’s initial electrolysis of brine
- invention of the dynamo for large-scale electricity generation
- development of early diaphragm and mercury cell technologies
- faraday’s laws of electrolysis
Applications
- production of pvc plastic (from chlorine)
- water purification and disinfectants (chlorine and sodium hypochlorite)
- pulp and paper manufacturing (bleaching)
- production of soaps, detergents, and textiles (sodium hydroxide)
- chemical synthesis for a vast range of products
Patents:
Potential Innovations Ideas
Professionals (100% free) Membership Required
You must be a Professionals (100% free) member to access this content.
AVAILABLE FOR NEW CHALLENGES
Mechanical Engineer, Project or R&D Manager
Available for a new challenge on short notice.
Contact me on LinkedIn
Plastic metal electronics integration, Design-to-cost, GMP, Ergonomics, Medium to high-volume devices & consumables, Regulated industries, CE & FDA, CAD, Solidworks, Lean Sigma Black Belt, medical ISO 13485
We are looking for a new sponsor
Your company or institution is into technique, science or research ?
> send us a message <
Receive all new articles
Free, no spam, email not distributed nor resold
or you can get your full membership -for free- to access all restricted content >here<
Historical Context
Chloralkali Process
(if date is unknown or not relevant, e.g. "fluid mechanics", a rounded estimation of its notable emergence is provided)
Related Invention, Innovation & Technical Principles