Membrane electrolytic cell for minimizing hypochlorite and chlorate

Abstract

An electrolytic cell for the electrolysis of an alkali metal chloride brine is comprised of an anode compartment and a cathode compartment separated by a cation exchange membrane. The anode is comprised of an unflattened expanded structure of a valve metal selected from the group consisting of titanium, tantalum, niobium, and alloys thereof. At least one side of the anode has as the electrochemically active surface an electrodeposited layer of a valve metal oxide. A plurality of cracks traverse the electrodeposited layer and a coating of a platinum metal group oxide covers the electrodeposited layer and substantially fills the cracks. The cationic exchange membrane is comprised of a laminated structure having a first surface adapted to contact an anolyte in which the ion exchange groups are predominately sulfonic acid groups. The first surface is also in contact with the electrochemically active surface of the anode. A second surface of the cation exchange membrane, adapted to contact a catholyte, has ion exchange groups which are predominately carboxylic acid groups. The cathode positioned in the cathode compartment is spaced apart from the cation exchange membrane. The cell operates with both a low chlorine overvoltage and a low oxygen overvoltage. During electrolysis of alkali metal chloride brines, the formation of hypochlorite and chlorate ions is minimized and the alkali metal hydroxides produced have low chlorate concentrations and are suitable for use without further treatment in chlorate-sensitive applications. Spent brine treatment is simplified and at reduced costs.