Performance Evaluation of Electrolyzer Report

Date : 7-02-2023
Plant : CAP
Prepared by Aiman M I
1. Introduction
As an energy-intensive industry, the chlor-alkali process has caused issues due to heavy electricity
consumption. Chlor-alkali electrolysis takes a key role in this process. The performance of the
electrolyzer should be evaluated.
2. Evaluation Standard
The first step is for the evaluator to determine the appropriate calculation that applies to the equipment
to be evaluated. Calculations are made based on the calculation formula provided by the licensor. The
data were taken from two sources like control room and the laboratory. The performance of the
electrolyzer is approached by current efficiency. The formula of current efficiency is shown below.
Qi ∗Ci − Qo∗Co 2∗ O2
CE=1 − ∗100 − − LC
I ∗ N ∗ 0.0373 Cl 2
3. Result
The electrolyzer monitoring on Tuesday, February 7 2023 is shown below.
Table 1. The recapitulation of data on February 7 2023

Catholyte Temp. Acidity inlet Acidity outlet Current Membrane Anode/Cathode Suggested
Load Voltage pH
R-230 (TI 220) anolyte anolyte Efficiency Lifetime Lifetime HCl Injected

kA V degree C Max. 0.15 N 0.001N-0.005N % Months Months L/h

A 10,54 463,20 86,20 0,07326 0,00427 95,82 5 107 141,90 2,13
B 11,17 463,20 86,60 0,04684 0,00222 96,61 4 107 129,70 2,72
C 10,70 464,70 87,70 0,05106 0,00327 96,59 3 110 149,30 2,40
D 11,25 464,70 86,60 0,04507 0,00372 96,79 2 111 122,60 2,61
E 11,16 460,00 88,00 0,09035 0,00466 95,21 24 96 205,10 2,04
F 11,27 460,00 86,20 0,10501 0,00438 94,51 24 96 241,10 2,10
G 10,38 437,10 82,70 0,08103 0,00355 95,48 22 21 167,20 2,32
H 10,08 437,10 81,70 0,06593 0,00411 96,19 29 27 145,40 2,18
I - - - - - - 14 14 - -
J 11,35 289,70 85,00 0,05617 0,00294 96,22 20 87 90,20 2,50
K 11,74 289,70 87,20 0,09812 0,00450 94,58 19 82 136,10 2,08
L 12,37 289,70 85,80 0,06682 0,00394 96,05 20 80 94,80 2,22
M 11,71 289,70 84,30 0,05550 0,00383 96,43 20 86 90,20 2,25
N - - - - - - 13 13 - -
O 12,94 264,20 76,60 0,07037 0,00655 96,36 26 25 82,40 1,69
P 12,76 264,20 78,00 0,06016 0,00477 96,56 26 25 110,20 2,02
Q 12,94 263,40 77,00 0,04906 0,00344 96,83 10 11 90,80 2,35
R 12,93 263,40 77,70 0,04973 0,00422 96,92 9 9 90,30 2,15
S 16,05 426,00 82,40 0,05395 0,00272 96,44 17 35 203,80 2,56
T - - - - - - 37 35 - -
Note:
Based on table 1, the acidity of outlet anolyte at electrolyzer O is higher than the maximum range. The
value of acidity outlet affected to the current efficiency. The value of pH still need to be adjusted to the
normal range for electrolyzer O. Some electrolizers such as I, N, and T did not operate, while the
electrolizers O and P are operated with the low current. This conditions caused by a decrease in
production capacity.

The data collected from table 1, then the data is described in graphical form so that it is easy to
understand.

98.50
97.50
96.50
95.50
94.50
93.50
92.50
91.50
90.50
89.50
19-May-22 8-Jul-22 27-Aug-22 16-Oct-22 5-Dec-22 24-Jan-23 15-Mar-23

A B C D

Figure 1. Rectifier 1 electrolyzer

Note:
a. R-230-A : Current efficiency slightly decrease and the voltage remain constant compare with the
previous date.
b. R-230-B : Current efficiency slightly decrease of performance and the voltage remain constant.
c. R-230-C : Current efficiency slightly decrease and the voltage remain constant compare to
previous voltage.
d. R-230-D : Current efficiency slightly enhance of performance and the voltage remain constant.

97.50
97.00
96.50
96.00
95.50
95.00
94.50
94.00
93.50
93.00
92.50
92.00
19-May-22 8-Jul-22 27-Aug-22 16-Oct-22 5-Dec-22 24-Jan-23 15-Mar-23

E F G H
Figure 2.
Rectifier 2 electrolyzer
Note:
a. R-230-E : Current efficiency slightly enhance compare to previous date and the voltage
remain constant compare with the previous date.
b. R-230-F : Current efficiency slightly decrease compare to previous date and the voltage remain
constant.
c. R-230-G : Current efficiency slightly enhance and the voltage remain constant compare to
previous voltage.
d. R-230-H : Current efficiency slightly decrease compare to previous date and the voltage remain
constant compare with the previous date.

97.20
96.60
96.00
95.40
94.80
94.20
93.60
93.00
92.40
19-May-22 8-Jul-22 27-Aug-22 16-Oct-22 5-Dec-22 24-Jan-23 15-Mar-23

J K L M
F
igure 3. Rectifier 3 electrolyzer
Note:
a. R-230-J : Current efficiency slightly decrease compare to previous date and the voltage remain
constant.
b. R-230-K : Current efficiency slightly enhance and the voltage remain constant.
c. R-230-L : Current efficiency slightly enhance to previous date and the voltage remain constant.
d. R-230-M : Current efficiency slightly enhance and the voltage remain constant.

97.20
96.80
96.40
96.00
95.60
95.20
94.80
94.40
19-May-22 8-Jul-22 27-Aug-22 16-Oct-22 5-Dec-22 24-Jan-23 15-Mar-23

O P Q R
Figure 4. Rectifier 4 electrolyzer
Note:
a. R-230-O : Current efficiency slightly decrease compare to previous date and the voltage decrease
compare with the previous date. The current decrease from 15.86 kA to 12.94 kA. The
value of pH still need to be adjusted to the normal range for electrolyzer O.
b. R-230-P : Current efficiency slightly enhance and the voltage decrease. The current decrease from
15.75 kA to 12.76 kA.
c. R-230-Q : Current efficiency enhance compare to previous date and the voltage remain constant
compare to previous voltage.
d. R-230-R : Current efficiency slightly decrease from previous date and the voltage remain constant
compare with the previous date.

97.00
96.50
96.00
95.50
95.00
94.50
94.00
19-May-22 8-Jul-22 27-Aug-22 16-Oct-22 5-Dec-22 24-Jan-23 15-Mar-23

I N
Figure 5. Rectifier 5 electrolyzer

Note:
a. R-230-I : The electrolyzer I is not operated (The last data were taken on January 31 2023).
b. R-230-N : The electrolyzer N is not operated (The last data were taken on January 31 2023).

98.00
97.00
96.00
95.00
94.00
93.00
92.00
91.00
19-May-22 8-Jul-22 27-Aug-22 16-Oct-22 5-Dec-22 24-Jan-23 15-Mar-23

S T
F
igure 6. Rectifier 6 electrolyzer

Note:
a. R-230-S : Current efficiency slightly enhance compare to the previous date and the voltage
remain constant.
b. R-230-T : The electrolyzer T is not operated (The last data were taken on January 31 2023).