US 20070007146A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2007/0007146 A1
Childers, 11 et al. (43) Pub. Date: Jan. 11, 2007

(54) PROCESS FOR PRODUCING (52) US. Cl. ............................................................ .. 205/501

HYPOCHLORITE

(75) Inventors: Harold E. Childers II, Houston, TX (57) ABSTRACT

(US); Lucette Falcon, (US); Rudolf C.
Matousek, Sugarland, TX (US) In a process for producing sodium hypochlorite in an
electrolytic cell comprises forming an aqueous based chlo
Correspondence Address: ride solution With a chloride salt; controlling the concentra
D’AMBROSIO & ASSOCIATES, P.L.L.C. tion of chloride Within the solution to an amount comprising
10260 WESTHEIMER less than 25 g/L chloride salt; piping the salt solution to the
SUITE 465
electrolytic cell, the electrolytic cell comprising an anode
HOUSTON, TX 77042 (US) and a cathode, the cathode comprising a metallic base
material, a ?rst coating on the metallic base material and a
(73) Assignee: Severn Trent Water Puri?cation, Inc. second non-conductive ceramic coating on the metallic base
material. The chloride solution is then in contact With the
(21) Appl. No.: 11/176,848
anodes and cathodes and an electric current is sent through
(22) Filed: Jul. 7, 2005 out the electrolytic cell to produce hypochlorite. During this
process the electric current is controlled so that the poWer
Publication Classi?cation consumption is less than 2.5 kWh per pound of hypochlorite
produced and the resulting cell e?iciency comprises less
(51) Int. Cl. than 2.5 kg of chloride salt consumed for every 1 kg of
C25B 1/26 (2006.01) hypochlorite generated.
Patent Application Publication Jan. 11, 2007 US 2007/0007146 A1

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US 2007/0007146 A1
PROCESS FOR PRODUCING HYPOCHLORITE
FIELD OF THE INVENTION
[0001] This invention relates generally to a process for
producing hypochlorite. More speci?cally, this invention
relates to a process of electrolytic production of hypochlorite
from salt containing chlorides in an aqueous solution.
BACKGROUND OF THE INVENTION
[0002] Chlorine in the form of hypochlorite Was ?rst used
for disinfecting Water systems in London after an outbreak
of cholera in 1850. For the past century, chlorination has
become the standard Way to disinfect Water supplies, potable
Water, WasteWater, and swimming pools, to eliminate epi
demic Waterbome diseases. The traditional Way to disinfect
Water With chlorine Was through the use of chlorine gas.
Transporting bulk chlorine on croWded highWays and into
residential areas has become a major safety concern since
the transport of chlorine gas under high pressure can be very
haZardous. Also, the transport of commercial hypochlorite,
Which is predominantly Water, is very expensive. Stringent
regulation of toxic gasses and accidental releases of chlorine
and higher costs have caused alternative sources for chlorine
to be sought for Water disinfection. Onsite production of a
chlorine source, sodium hypochlorite for example, is cur
rently the best option for obtaining a less expensive and safer
source.
[0003] On-site generation has proven itself as a safe and
cost ef?cient process for providing for the chlorine needs of
Water treatment facilities. On-site hypochlorite generation
has been accomplished by different means in the past. The
preferred on-site reaction is creating sodium hypochlorite
(NaOCl) according to the folloWing equation:
[0004] There is a great need to improve the electrolytic
production of hypochlorite from chloride-containing salts
dissolved in an aqueous solution. Problems that occur during
the reaction affect the amount of hypochlorite produced,
chlorate formation for example. Problems that occur in the
market place, such as the availability and cost of salt and
electrical poWer, affect the economy of hypochlorite pro
duction. Reducing salt and poWer consumption as Well as
making the process more ef?cient With improved current
ef?ciency is desired to reduce costs. The acceptable current
ef?ciency under prior methods for producing hypochlorite
ranged from 65% to above 75%. Prior electrolytic processes
have attempted to achieve such results using different meth
ods.
[0005] Early on in the development of chlorine cells used
for sodium chlorate manufacture, a ?lm-coated cathode for
the electrolysis of alkali metal halide solutions Was used in
the substantial absence of chromium ions. The cathode
comprised a conductive substrate, such as titanium, steel,
iron, or alloys thereof, coated With an adherent, porous ?lm
of a substantially nonconductive material having an average
coating thickness of less that about 103 microns. The non
conductive, ?lm-forming material Was further characteriZed
as being chemically inert in the halite solution. According to
the patent, this permitted electrolytic operation With
enhanced current ef?ciency Without the use of chromate ions
in the solution.
Jan. 11, 2007
[0006] In another method, a substrate metal, such as a
valve metal as represented by titanium, is provided With a
highly desirable rough surface characteristic for subsequent
coating application. This can be achieved by various opera
tions including etching to ensure a roughened surface mor
phology. In subsequent operations, a barrier layer is pro
vided on the surface of enhanced morphology. This may be
achieved by operations including heating, as Well as includ
ing thermal decomposition of a layer precursor. Subsequent
coatings provide enhanced lifetime even in the most rugged
commercial environments.
[0007] Electrode assemblies and cells for electrolytic pro
cesses have been improved for the production of alkali metal
hypochlorite, alkali metal chlorate, and other inorganic and
organic chemical products. One disclosure taught a dia
phragm-less electrolytic cell having at least one assembly of
a plurality of planar, parallel, closely spaced foraminous
dimensionally stable substantially horiZontally disposed
anodes and a plurality of parallel foraminous cathodes
substantially horiZontally disposed, the cathodes interleaved
With the anodes in substantially face-to-face closely spaced
parallel alignment. Organic chemical products, alkali metal
hypochlorite and alkali metal chlorate are produced by
placing the assembly of electrodes provided With a means
for supplying current to the individual anodes and current
from the individual cathodes, in alkali metal halide solu
tions, solutions of organic electrolytes and electrolyZing the
solutions While maintaining operating parameters suitable
for the production of alkali metal hypochlorite and alkali
metal chlorate and organic chemical products.
[0008] One improved process for the electrolysis of sea
Water comprised admixing sea Water before electrolysis With
suf?cient recycled hypochlorite solution to substantially
oxidiZed bromine, iodine and sulfur ion impurities to their
elemental forms for removal. Another method for chlorine
production Was directed to an alkali metal chlorate cell using
solid salt and a cell With higher temperatures so that a brine
feed solution replaced a solid salt feed. One further process
of producing sodium hypochlorite comprised electrolyZing
an aqueous solution of sodium chloride. The use of at least
one cooling means in or betWeen the electrolytic cells to cool
the electrolyte solution preferably betWeen 5° C. and 45° C.
Was found to increase available chlorine.
[0009] It is the amount of available chlorine in the result
ing solution that determines the efficiency of the hypochlo
rite generation process. Competing reactions, such as the
reverse reaction back to NaCl and H20 or the formation of
sodium chlorates, occur in the resulting sodium hypochlorite
solution produced from the initial reaction. The amount of
sodium hypochlorite lost to side reactions, chlorate forma
tion and back reactions, is proportional to greater concen
trations of available chlorine and higher temperatures. The
temperature of aqueous solutions used in the reaction has
been found to affect the resulting amount of sodium
hypochlorite produced.
DEFINITIONS/ EQUATIONS
[0010] Cell Efficiency: Cell ef?ciency is a ratio of the
concentration of chloride salt Within the aqueous brine
solution fed to the electrolytic cell to concentration of
hypochlorite in the el?uent of the electrolytic cell. For
US 2007/0007146 A1 Jan. 11, 2007

example, in the case of an NaCl solution the cell ef?ciency

is calculated by the following equation: -continued
4 5
1 mol c12 70.9lg c12
NaCl g/L
c611 E .NaCl NaOCl =
ff [ / ] NaOCl g/L

[0024] Dividing the grams of ClZ/Hr by the How rate

results in g/L C12.
[0011] PoWer Consumption DC: PoWer consumption is
expressed as kWatt-Hours/NaOCl Lb. PoWer consump
tion is calculated by the following equations:
i
g Cl2/Hour i Hour = Cl ll‘t Th .
liter/minutesX 60 minutes g 2 1 er(g/L e0)

Amps * Volts : Watts

kWatts Day 24 Hour _

DC Am
P8X
DC v lt
0 W 1000 Watts ><NaOC1Lb(as C12) X Day
[0025] Current Efficiency is then calculated by comparing
the actual amount of hypochlorite produced With the
Power Cons. DC theoretical amount of hypochlorite using the the folloWing
equation:
[0012] Current Efficiency: Current e?iciency is the mea
surement of available chlorine produced during electroly NaOCl g/L Actual
X 100 = Current Eff.%
sis in relation to the poWer or current consumed and is NaOCl g/L Theo.
based on Faraday’s laW. Faraday’s LaW states that the
amount of substance (number of moles) consumed or
produced at one of the electrodes in an electrolytic cell is
directly proportional to the amount of electricity that SUMMARY
passes through the cell (number of moles of electrons [0026] Reducing salt and poWer consumption as Well as
transferred at that electrode) Current e?iciency is making the process of hypochlorite production more e?i
expressed as a percent calculation based on Faraday’s laW cient With improved current ef?ciency is desired to reduce
and the production of sodium hypochlorite as folloWs: costs. The process of this invention generates hypochlorite,
either in the form of sodium hypochlorite or potassium
[0013] First, the theoretical amount of sodium hypochlo
hypochlorite, in terms of available chlorine, more ef?ciently,
rite (g/ L Theo.) that should be produced in an electrolytic that is With a reduction of feed product consumed or energy
cell is calculated using the folloWing:
required to produce equivalent amounts of hypochlorite as
[0014] Equation Terms 1-6 previous methods. Increased e?iciency is measured by an
increase in the percentage of sodium or potassium chloride
[0015] l. The amount of Current (Amps) converted to hypochlorite during the electrolytic process and
[0016] 2. The amount of electric charge that ?oWs through a decrease in poWer consumption.
the cell [0027] Temperature can also affect the ef?ciency of the
[0017] 3. Faraday’s Constant 96500 C/mol e. process. Higher temperatures of the solution during elec
trolysis and increased concentrations of available chlorine
[0018] 4. The electron mole to Chlorine mole ratio based enhance the probability of a shift in kinetics to form unde
on the balanced equation. sirable by products. The amount of available chlorine, the
desired end product, is reduced. Because of these side
[0019] According to the balanced equation for the reac reactions, more sodium chloride and electric current must be
tion that occurs at the anode of this cell, one mole of consumed to produce an equal amount of available chlorine.
chlorine for every 2 moles of electrons. Advantageously, during the process of this invention, the
amount of chloride salt consumed during the electrolysis
process is reduced While maintaining both cell efficiency and
[0020] 5. The atomic mass unit of Chlorine
current ef?ciency. Side reactions are reduced thereby alloW
[0021] (used to express the amount of Sodium ing greater production of available chlorine. The current
Hypochlorite) ef?ciency of the process can be increased so that the current
ef?ciency is Within a range of from about 70% to about 80%.
[0022] 6. The number of cells Improved ef?ciency translates to cost savings in terms of
[0023] The equation is beloW Where terms 2 -5 are con
feed product and electric poWer consumption.
stants and l & 6 are variables: [0028] Therefore, disclosed herein is a process for pro
ducing a hypochlorite solution in an electrolytic cell. In one
embodiment, the process comprises forming an aqueous
2 3 based chloride solution With a chloride salt. Preferably, the
1 3600 C 1 mol 2’
DC Amps>< X X concentration of chloride Within the solution is controlled to
Amp-Hour 96,500 C an amount comprising less than 20 g/L chloride salt. The salt
solution is piped to the electrolytic cell. The electrolytic cell
US 2007/0007146 A1
comprises an anode and a cathode. The cathode preferably
comprises a metallic base material, a ?rst coating on the
metallic base material and a second non-conductive ceramic
coating on the metallic base material. The chloride solution
is alloWed to contact the anode and to contact the cathode.
An electric current is passed throughout the electrolytic cell
to produce hypochlorite. Preferably, the electric current is
controlled so that the poWer consumption is less than 2.3
kWh per pound of hypochlorite produced, the cell ef?ciency
comprises less than 2.5 kg of chloride salt consumed for
every 1 kg of hypochlorite generated.
[0029] In one embodiment for producing a hypochlorite
solution according to the present invention the salt solution
comprises sodium chloride, the amount of sodium chloride
consumed during the process comprising less than 2.5 kg for
every 1 kg of hypochlorite generated.
[0030] In one embodiment for producing a hypochlorite
solution according to the present invention the metallic base
material is selected from a group comprising titanium, iron,
steel, copper and nickel alloys, and the ?rst coating com
prises an oxide of the metallic base material. The second
coating can comprise a non-conductive ceramic selected
from a group comprising yttria-stabiliZed Zirconia, Zirconia,
titania, chromia and hastelloy. Advantageously, in this pro
cess for producing a hypochlorite solution, the current
ef?ciency is greater than 70% even though the salt feed is
decreased beloW 20 g/L. In another embodiment for pro
ducing a hypochlorite solution according to the present
invention the temperature of the solution is maintained
Within a range of about 15° C. to less than 60° C.
[0031] In an alternative embodiment, a process for pro
ducing a hypochlorite solution in an electrolytic cell com
prises steps (a) thru (g). In step (a) an aqueous based chloride
solution is formed With a chloride salt. In step (b) the
concentration of chloride Within the solution is controlled to
an amount comprising less than 20 g/L chloride salt. In step
(c), the salt solution from step (a) is piped to the electrolytic
cell, the electrolytic cell comprising an anode and a cathode,
the cathode comprising a metallic base selected from a
group comprising titanium, iron, steel, copper and nickel
alloys, a ?rst coating on the metallic base comprising an
oxide of the metallic base material, and a second coating on
the oxide of the metallic base material comprising a non
conductive ceramic. In step (d) the chloride solution is
alloWed to contact the anode. In step (e) the chloride solution
is alloWed to contact the cathode. In step (f) an electric
current is passed throughout the electrolytic cell to produce
hypochlorite. Finally, in step (g) the electric current is
controlled so that the poWer consumption is Within a range
of about 1.8 kWh per pound of hypochlorite produced to
about 2.5 kWh per pound of hypochlorite produced, Wherein
the cell ef?ciency comprises less than 2.5 kg of chloride salt
for every 1 kg of hypochlorite generated and the current
ef?ciency is maintained at greater than 70%.
[0032] In one preferred embodiment for producing a
hypochlorite solution, the chloride solution comprises less
than 20 g/L chloride salt and the chloride salt can be selected
from sodium chloride or potassium chloride. The cathode
can comprise a titanium base for conducting electrons, a ?rst
coating on the titanium base, the ?rst coating comprising
titanium oxide, and a non-conductive yttria-stabiliZed Zir
conia second coating applied to the titanium ?rst coating.
Jan. 11, 2007
The electric current can be controlled so that poWer con
sumption is Within a range of about 1.5 kWh per pound of
hypochlorite produced to about 2.0 kWh per pound of
hypochlorite produced. The temperature is maintained
Within a range of about 150 C. to about 600 C. Cell ef?ciency
comprises less than 2.5 kg of chloride salt consumed for
every 1 kg of hypochlorite generated and the current effi
ciency is maintained at greater than 70%.
[0033] An alternative process for producing a hypochlo
rite solution in an electrolytic cell comprises forming an
aqueous based chloride solution With a chloride salt, the
chloride solution comprising an amount ranging from 25 g/ L
to 30 g/L. In another alternative embodiment, the chloride
solution is greater than 30 g/L chloride salt. The salt solution
is piped to the electrolytic cell, the electrolytic cell com
prising an anode and a cathode, the cathode comprising a
metallic base selected from a group comprising titanium,
iron, steel, copper and nickel alloys, a ?rst coating on the
metallic base comprises an oxide of the metallic base
material, and a second coating on the oxide of the metallic
base material comprises a non-conductive ceramic. The
chloride solution is alloWed to contact the anode and the
cathode. An electric current is passed throughout the elec
trolytic cell to produce hypochlorite. During the process, the
poWer consumption is controlled Within an amount com
prising less than 2.0 kWh per pound of hypochlorite pro
duced so that the cell ef?ciency comprises less than 3.0 kg
of chloride salt consumed for every 1 kg of hypochlorite
generated and the current e?iciency is maintained at greater
than 80%.
BRIEF DESCRIPTION OF DRAWINGS
[0034] FIGURE is a schematic of one embodiment of this
invention.
DETAILED DESCRIPTION OF THE
INVENTION
[0035] According to the practice of the process of this
invention hypochlorite is generated more ef?ciently. In this
instance, more e?iciently means With a reduction of either
feed product consumed or energy required to produce
equivalent amounts of hypochlorite as previous methods.
Cell ef?ciency is a ratio of the amount of chloride salt
converted to hypochlorite during the electrolytic process.
Cell ef?ciency indicates the amount of chloride salt con
sumed per unit of hypochlorite produced. The object of this
invention is to decrease the amount of sodium chloride
consumed thereby resulting in a decrease in the cell effi
ciency ratio. Current ef?ciency is based on a decrease in
poWer consumption as expressed in actual hypochlorite
produced divided by theoretical hypochlorite under Fara
day’s LaW. Advantageously, the present process consumes
less chloride salt Without a loss of ef?ciency as Will be
shoWn in the examples described beloW and accompanying
tables.
[0036] Higher temperatures of the solution used during
electrolysis and increased concentrations of available chlo
rine enhance the probability of a shift in kinetics to form
undesirable by products. The amount of available chlorine,
Which is the desired end product, is reduced by these side
reactions. Because of the side reactions during previously
knoWn processes, more sodium chloride and electric current
US 2007/0007146 A1
had to be consumed to produce an equal amount of available
chlorine. Advantageously, during the process of this inven
tion, the amount of chloride salt consumed during the
electrolysis process is reduced While maintaining both cell
ef?ciency in terms of number of kilograms of chloride salt
consumed per kilogram of hypochlorite produced as Well as
current ef?ciency based on poWer consumption. Side reac
tions are reduced thereby alloWing greater production of
available chlorine. The current ef?ciency of the process can
be increased so that the current ef?ciency is Within a range
of from about 70% to about 80%. Improved current effi
ciency translates to cost savings in electric poWer consump
tion. A decrease in cell ef?ciency ratio is desired because it
indicates a decrease in the amount of salt consumed and
therefore a decrease in cost.
[0037] One preferred process can generate hypochlorite
by using a sodium or potassium salt as the starting product
resulting in sodium hypochlorite or potassium hypochlorite,
respectively. For purposes of this description, but not as a
limitation, sodium chloride Will be used as the feed product.
Prior technology taught that commercially feasible electro
lytic cells Were capable of producing 8 to 10 g/L of available
chlorine While consuming approximately 28-30 g/L of
sodium chloride, using a poWer consumption of 2.3 to 2.44
kWh per pound of hypochlorite produced and comprising a
cell e?iciency of 3.0 to 3.5 grams of salt per gram of chlorine
produced. See J. E. Bennett, Non-Daiphragm Electrolytic
Hypochlorite Generators, Chemical Engineering Progress,
December, 1974. Current e?iciency as described in the
Bennett process is Within the 60% to 65% range. Advanta
geously, the present process for producing a hypochlorite
solution uses less chloride salt Without a loss of current
ef?ciency. During the process, an aqueous based chloride
solution is formed With a chloride salt by controlling the
concentration of chloride Within the solution to an amount
comprising less than 20 g/L chloride salt While maintaining
a poWer consumption at less than 2.3 kWh per pound of
hypochlorite produced and comprising a cell e?iciency of
2.5 kg or less of chloride salt consumed for every 1 kg of
hypochlorite generated. Current ef?ciency resulting from the
present process is above 70%.
[0038] Referring to the schematic of the FIGURE, solid
salt Within a brine tank 40 combines With Water piped to the
brine tank from a Water softener unit 15. The solid salt can
be in the form of sea salt or mined salt. Water may be treated
in a Water softener unit to remove calcium and magnesium.
These impurities are prone to form insulating precipitates
betWeen the electrodes, Which inhibit the electrolytic pro
cess. This reduces the conversion ef?ciency and increases
maintenance costs. Salt solution 44 for the electrolysis
process is piped to an electolyZer assembly 20 from the brine
tank 40 through pipelines 42. In one embodiment, the cells
are arranged in bipolar con?guration. Brine 44 from the
brine tank 40 is piped to an inlet pipe 26a of the ?rst cell 26
in the electrolyZer assembly 20 and can be mixed With
chilled Water piped 32 from a chiller 30. The use of chilled
Water piped to each cell Within an electrolytic assembly 20
is taught by Bass, US. Pat. No. 6,805,787 and is hereby
incorporated as if fully reproduced. Both the chiller 30 and
the Water softener unit 15 are knoWn in the art and readily
available. The system is controlled by an operator-controlled
computer. In another embodiment of the process of this
invention, the process can ef?ciently be practiced Without a
chiller, Wherein temperatures are maintained Within a range
Jan. 11, 2007
of 15° C. to 600 C. While current ef?ciency remains at above
70%. These temperature ranges are important especially in
geographic areas Where the process Will be used such as the
southern hemispheres and parts of the World, the middle east
or southern U.S., Where ambient temperatures are high
during the summertime.
[0039] After the salt solution is formed, the brine solution
enters the casings of the assembly and ?oods the cells 26, 24,
22. A DC current impressed upon the electrolyZer converts
the sodium chloride to molecular chlorine and sodium
hypochlorite Within the cells. Unreacted brine and hydrogen
gas, a product of electrolysis, remain in the solution until the
hydrogen gas is removed from the generation Zone by
thermal convection, passes through gas ports in the com
partment partitions and is ?nally vented to the atmosphere.
The electrolysis reaction is as folloWs:
Anode (+)
ZNaCL + 2H20
C12 \ NaOCl + H2 + NaCl + H20
ZNaOH + H2 /
Cathode (——)
[0040] The brine, electrolyte and hypochlorite pass from
one compartment to the next through ports located beloW the
solution level. In multiple cell electrolyZer assemblies 20,
the brine and hypochlorite solution passes through an outlet
connection from the ?rst cell and is piped to the inlet of the
next electroylyZer cell. In one embodiment, the solution can
be mixed With chilled Water piped from the chiller 30 as it
passes from one cell to the next. In the ?nal cell, the brine,
electrolyte and sodium hypochlorite together With any
remaining hydrogen gas are piped to the storage tank 60
Which is designed to scavenge the hydrogen from the ?nal
product. A dosing pump 66 Will pump the hypochlorite to a
user system requiring disinfecting, a WasteWater tank or
commercial sWimming pool for example.
[0041] Increased efficiency is measured by a reduction in
the amount of feed product, sodium chloride for example,
consumed during the process and a decrease in poWer
consumption. The current ef?ciency of this method is pref
erably Within a range of from about 70% to about 80%.
[0042] One preferred process for generating sodium
hypochlorite uses an electrolyZer assembly having electro
lyZer cells or tubes stacked one upon another. Each electro
lyZer cell comprises compartments having anode and cath
ode-plates. The number of anode/ cathode compartments can
range from about 1 compartment to about 15 compartments
depending on the length of the cell, preferably 4 to 12
compartments per cell. Altemately, the electrolyZer cell can
use bipolar plates having an anode and a cathode on the
same plate as is knoWn in the industry. Each compartment
comprises from 5 to 25 bipolar plates. The electrolyZer cell
is manufactured and available from Severn Trent Services
Water Puri?cation Solution Inc.
[0043] A preferred electrolytic cell of the invention uti
liZes a coated cathode. The cathode comprises a metallic
base material, a ?rst coating on the metallic base material
and a second non-conductive ceramic coating on the metal
US 2007/0007146 A1 Jan. 11, 2007

lic base material. The metallic base material can comprise
electrically conductive substrate such as titanium substrate.
The term titanium as used herein is meant to include
commercial titanium and titanium alloys such as grade 5
titanium. Other electrical conductive substrates Which may
be used include iron, steel, copper and copper-nickel alloys
With titanium being preferred. The cathode substrate may be
sand blasted or etched before any coatings are applied. A
?rst coating is applied to the substrate in the form of an oxide
of the metallic base material, titanium oxide for example.
The oxide coating is applied prior to applying the ceramic
coating to improve bonding of the coating to the substrate
surface. A second coating is applied onto the oxide ?rst
coating. The second coating is a non-conductive ceramic
coating. The second coating comprises a non-conductive
ceramic selected from a group comprising yttria-stabiliZed
Zirconia, Zirconia, titania, chromia and hastelloy. The coat
ing may be applied by plasma spraying after the surface of
the cathode substrate is suitably clean by chemical degreas
ing. Other methods of applying the yttria-stabiliZed Zirconia
coating may be used, including ?ame spraying, chemical
deposition, thermal spraying and sputtering.
[0044] The sodium chloride solution, chilled or at ambient
temperatures, that is from 15° C. to 60° C., is alloWed to
end product, sodium hypochlorite is piped to a storage tank
60 and then to a user’s system that requires disinfecting by
a dosing.
[0047] The folloWing examples illustrates the test results
for sodium hypochlorite produced according to the process
of this invention.
EXAMPLES
Test ProcedureiExample 1
Standard Cell
[0048] A chloride brine Was fed into a test electrolytic cell
at a brine feed rate equivalent to 12-16 gallons per pound of
product produced. This cell had no technological improve
ments such as coated cathodes or chilled solutions. The
concentration of chloride salt Within the brine solution Was
maintained betWeen 28-30 grams per liter. The liquid ?oW
rate Was maintained so as to maintain the same exit
hypochlorite concentration if the cell ef?ciency remained
constant. Temperatures Were ambient. In this Way, any
improvement in future tests for hypochlorite concentration is
related to improved cell ef?ciency. A baseline performance
pro?le With the above operating conditions and titanium
cathodes Was obtained.

Process for Producing Hypochiorite

Example I
Test Power Cell Inlet Cell Outlet NaCl Eff. Grams NaoCl GPL Current
# Cons. DC Temp Temp GPL NaCl/NaoCl GPL Theo. Eff. %

1 2.2 20 45 33 3.64 9.08 14.3 63.5

2 2.02 20 45 30 3.21 9.36 13.7 68.4
3 1.99 23 45 30 3.18 9.43 13.6 69.3
4 2.08 20 45 33 3.5 9.43 14.2 66.5
5 2.09 20 45 33 3.55 9.29 14 66.2

contact the anode and then the cathode. The salt concentra
tion throughout the process is maintained at less than 25 g/ L
chloride salt. In one preferred embodiment, the salt concen
tration is maintained at less than 20 g/L. An electric current
is passed throughout the electrolytic cell to produce
hypochlorite. The electric current is controlled so that the
poWer consumption is less than 2.3 kWh per pound of
hypochlorite produced, preferably Within a range of 1.8 to
2.3 kWh per pound of hypochlorite produced. The current
ef?ciency With this concentration of chloride salt and this
amount of poWer consumption is greater than 70%.
[0045] In another embodiment of this invention, the salt
concentration is increased to betWeen 25-30 g/L and the
electric current is controlled so that poWer consumption is
Within a range of 1.5 kWh to 2.0 kWh per pound of
hypochlorite produced. The cell ef?ciency of this process
comprises less than 2.5 kg of chloride salt consumed for
every 1 kg of hypochlorite generated. The temperature is
again Within a range of from 150 C. to 600 C. Current
ef?ciency for this embodiment increases to greater than
80%.
[0046] In another aspect of this invention, electrical cur
rent required for electrolysis is sent from a poWer source 80
to a recti?er 82 to convert alternating current to direct
current and delivered to each cell by poWer Wiring 84. The
[0049] The resultant current ef?ciency average 66.8% for
example 1. The hypochlorite concentration at the exit
point Was approximately 9 g/L. Approximately 3.5 g/L
salt Were used for each g/L hypochlorite produced, and the
poWer consumption averaged 2.01 kWh/pound hypochlo
rite produced.
Test ProcedureiExamples 2 and 3,
Having Improved Technology and Decreased Salt
Feed
[0050] The electrolytic cell Was operated at a brine feed
rate equivalent to 12-16 gallons per pound of product
produced, With an inlet brine solution concentration of 28-30
g/L salt. Titanium cathodes Were replaced With coated
cathodes. The salt concentration Was sloWly reduced at
intervals of approximately 5 g/L salt While maintaining a
constant liquid How to the cell. Target concentrations Were
25, 20, and 15 g/L. All operating conditions (independent
variables) Were maintained constant and resulting perfor
mance parameters (dependent variables) Were measured.
These include; exit hypochlorite concentration, cell effi
ciency, current ef?ciency, temperature, and salt usage per
pound of product. Temperatures Were ambient.
US 2007/0007146 A1 Jan. 11, 2007

Process for Producing Hypochiorite

Example 2

Test PoWer Cell Inlet Cell Outlet NaCl E?". Grams NaoCl GPL Current
# Cons.DC Temp Temp GPL NaCl/NaoCl GPL Theo. E?". %
1 1.57 21.0 48.0 21.0 2.18 9.64 11.5 84.1
2 1.57 22.0 44.0 18.0 2.05 8.79 11.2 78.7
3 1.49 23.0 48.0 27.0 2.88 9.36 11.0 84.9
4 1.88 24.0 53.0 18.4 2.13 8.65 12.0 71.9
5 1.92 23.0 53.0 18.0 2.15 8.37 11.8 71.1
6 1.90 22.0 52.5 18.0 2.15 8.37 11.5 72.7
7 1.88 24.0 53.0 18.0 2.13 8.44 11.5 73.3

[0051]

Example 3

Test PoWer Cell Inlet Cell Outlet NaCl E?". Grams NaoCl GPL Current
# Cons. DC Temp Temp GPL NaCl/NaoCl GPL Theo. E?". %

1 1.87 19.0 39.0 25.5 3.27 7.80 10.3 75.9

2 1.99 19.5 39.0 26.0 3.19 8.15 11.6 70.4
3 1.80 19.5 39.0 26.5 3.40 7.80 9 8 79.2
4 1.83 19.5 39.0 25.5 3.33 7.66 9.8 77.7
5 1.90 19.5 38.0 27.0 3.49 7.73 10.4 74.5

[0052] The resulting current ef?ciencies for Examples 2
and 3 Were above 70%. Example 2 typically has salt feed
averaging less than 20 g/L. The power consumption
averaged 1.7 kWh per pound of hypochlorite produced
and the cell ef?ciency averaged 2.23 g/L salt consumed
for each g/ L hypochlorite produced. Increased salt feed in
Example 3 resulted in an increase in cell ef?ciency ratio,
i.e. more feed salt used per gram of hypochlorite pro
duced.
[0053] The foregoing description is illustrative and
explanatory of preferred embodiments of the invention, and
variations in the size, shape, materials and other details Will
become apparent to those skilled in the art. It is intended that
all such variations and modi?cations Which fall Within the
scope or spirit of the appended claims be embraced thereby.
1. A process for producing a hypochlorite solution in an
electrolytic cell comprising:
(a) forming an aqueous based chloride solution With a
chloride salt;
(b) controlling the concentration of chloride Within the
solution to an amount comprising less than 20 g/L
chloride salt;
(c) piping the salt solution from step (a) to the electrolytic
cell, the electrolytic cell comprising an anode and a
cathode, the cathode comprising a metallic base mate
rial, a ?rst coating on the metallic base material and a
second non-conductive ceramic coating on the metallic
base material;
(d) alloWing the chloride solution to contact the anode;
(e) alloWing the chloride solution to contact the cathode;
(I) passing an electric current throughout the electrolytic
cell to produce hypochlorite; and
(g) controlling the electric current so that the poWer
consumption is less than 2.3 kWh per pound of
hypochlorite produced;
Wherein the cell ef?ciency comprises less than 2.5 kg of
chloride salt consumed for every 1 kg of hypochlorite
generated.
2. The process for producing a hypochlorite solution of
claim 1 Wherein the salt solution comprises sodium chloride,
the amount of sodium chloride consumed during the method
comprising less than 2.5 kg for every 1 kg of hypochlorite
generated.
3. The process of claim 1 Wherein the metallic base
material is selected from a group comprising titanium, iron,
steel, copper and nickel alloys, and the ?rst coating com
prises an oxide of the metallic base material.
4. The process of claim 1 Wherein the second coating
comprises a non-conductive ceramic selected from a group
comprising yttria-stabiliZed Zirconia, Zirconia, titania, chro
mia and hastelloy.
5. The process of claim 1 Wherein the current ef?ciency is
greater than 70%.
6. The process of claim 1 Wherein the temperature of the
solution is maintained Within a range of about 15° C. to less
than 60° C.
7. A process for producing a hypochlorite solution in an
electrolytic cell comprising:
(a) forming an aqueous based chloride solution With a
chloride salt;
(b) controlling the concentration of chloride Within the
solution to an amount comprising less than 20 g/L
chloride salt;
US 2007/0007146 A1
(c) piping the salt solution from step (a) to the electrolytic
cell, the electrolytic cell comprising an anode and a
cathode, the cathode comprising a metallic base
selected from a group comprising titanium, iron, steel,
copper and nickel alloys, a ?rst coating on the metallic
base comprising an oxide of the metallic base material,
and a second coating on the oxide of the metallic base
material comprising a non-conductive ceramic;
(d) alloWing the chloride solution to contact the anode;
(e) alloWing the chloride solution to contact the cathode;
(f) passing an electric current throughout the electrolytic
cell to produce hypochlorite; and
(g) controlling the electric current so that the poWer
consumption is Within a range of about 1.8 kWh per
pound of hypochlorite produced to about 2.5 kWh per
pound of hypochlorite produced;
Wherein the cell e?iciency comprises less than 2.5 kg of
chloride salt for every 1 kg of hypochlorite generated
and the current ef?ciency is maintained at greater than
70%.
8. The process of claim 7 Wherein the chloride solution
comprises less than 20 g/L chloride salt
9. The process of claim 7 Wherein the chloride salt is
selected from sodium chloride or potassium chloride.
10. A process for producing a hypochlorite solution in an
electrolytic cell comprising:
(a) forming an aqueous based sodium chloride solution;
(b) piping the sodium chloride solution formed in step (a)
to the electrolytic cell, the electrolytic cell comprising
an anode and a cathode, the cathode comprising a
titanium base for conducting electrons, a ?rst coating
on the titanium base, the ?rst coating comprising tita
nium oxide, and a non-conductive yttria-stabiliZed Zir
conia second coating applied to the titanium ?rst coat
111%;
(c) alloWing the chloride solution to contact the anode;
(d) alloWing the chloride solution to contact the cathode;
(e) passing an electric current from the anode through the
solution to the cathode to produce hypochlorite;
(f) controlling the electric current so that poWer consump
tion is Within a range of about 1.5 kWh per pound of
hypochlorite produced to about 2.0 kWh per pound of
hypochlorite produced; and
(g) maintaining the temperature Within a range of about
150 C. to about 600 C.;
Wherein the cell e?iciency comprises less than 2.5 kg of
chloride salt consumed for every 1 kg of hypochlorite
generated and the current ef?ciency is maintained at
greater than 70%.
11. The process of claim 10 Wherein the chloride solution
comprises less than 25 g/L chloride salt
12. A process for producing a hypochlorite solution in an
electrolytic cell comprising:
Jan. 11, 2007
(a) forming an aqueous based chloride solution With a
chloride salt, the chloride solution comprising an
amount greater than 25 g/ L chloride salt,
(b) piping the salt solution from step (a) to the electrolytic
cell, the electrolytic cell comprising an anode and a
cathode, the cathode comprising a metallic base
selected from a group comprising titanium, iron, steel,
copper and nickel alloys, a ?rst coating on the metallic
base comprises an oxide of the metallic base material,
and a second coating on the oxide of the metallic base
material comprising a non-conductive ceramic;
(c) alloWing the chloride solution to contact the anode;
(d) alloWing the chloride solution to contact-the cathode;
(e) passing an electric current throughout the electrolytic
cell to produce hypochlorite; and
(i) controlling the poWer consumption Within an amount
comprising less than 2.0 kWh per pound of hypochlo
rite produced;
Wherein the cell ef?ciency comprises less than 3.0 kg of
chloride salt consumed for every 1 kg of hypochlorite
generated and the current ef?ciency is maintained at
greater than 80%.
13. A process for producing a hypochlorite solution in an
electrolytic cell comprising:
(a) forming an aqueous based sodium chloride solution,
the chloride solution comprising less than 20 g/L chlo
ride salt;
(b) piping the sodium chloride solution formed in step (a)
to the electrolytic cell, the electrolytic cell comprising
an anode and a cathode, the cathode comprising a
titanium base for conducting electrons, a ?rst coating
on the titanium base, the ?rst coating comprising tita
nium oxide, and a non-conductive yttria-stabiliZed Zir
conia second coating applied to the titanium ?rst coat
111%;
(c) alloWing the chloride solution to contact the anode;
(d) alloWing the chloride solution to contact the cathode;
(e) passing an electric current from the anode through the
solution to the cathode to produce hypochlorite;
(i) controlling the poWer consumption so that the amount
of electrical poWer consumed comprises less than 2.0
kWh per pound of hypochlorite produced; and
(g) maintaining the temperature Within a range of about
150 C. to about60o C.;
Wherein the cell ef?ciency comprises less than 2.5 kg of
chloride salt consumed for every 1 kg of hypochlorite
generated and the current ef?ciency is maintained at
greater than 70%.