Pilot-scale study of membrane-coated cathodes: Achieving high cathodic efficiency and outstanding stability in chlorate electrolysis

Sodium chlorate (NaClO3) is primarily used for producing chlorine dioxide, an environmentally friendly bleaching agent for pulp. Currently, dichromate is used as an electrolyte additive in the chlorate process where it has several functions, but due to health and environmental risks associated with chromate, there is a need for a less toxic alternative. In the present study, we prepared a membrane-coated cathode as a substitute for chromium (VI), to keep a high current efficiency in chlorate electrolysis. This electrode employed an industrially relevant electrode with active catalysts as the substrate and a thin layer of ion exchange polymer as the coating. The coating effectively blocked anions such as ClO- and ClO3- from reaching the cathode, thereby suppressing cathodic side reactions. We conducted a series of electrochemical characterizations on the membrane-coated cathodes with varying coating thickness and tested them in a pilot-scale setup for efficiency and stability under industrial testing conditions.