An experimental study of a fixed bed chlor-alkali reactor

A 100 A continuous ‘flow-by’ chlor-alkali membrane reactor was constructed with both anode and cathode consisting of fixed beds of 0.6 to 1 mm diameter graphite particles. The reactor was operated over a range of conditions with and without co-current flow of air or oxygen to the cathode. With an anolyte of 5 M NaCl and catholyte 1.4–3 M NaOH the reactor produced sodium hydroxide and chlorine with ≥80% efficiency at temperatures 28–100°C, absolute pressure 270–970 kPa and superficial current density up to 3.3 kA m^?2. For operation at 100°C and an average pressure of 870 kPa with no gas delivered to the cathode, the cell voltage increased linearly from 2.5V at 0.3 kA m^?2 (10 A) to 4.0 V at 3.3 kA m^?2 (100 A). When oxygen was delivered to the cathode at 1 litre min^?1 under 870 kPa average pressure, the corresonding cell voltages were 1.6 V at 0.3 kA m^?2 to 3.4 V at 3.3 kA m^?2. In operation with air under the same conditions the cell voltage rose from 1.6 V at 0.3 kA m^?2 to 3.1 V at 1.6 kA m^?2. The performance of the oxygen cathode deteriorated with lower pressure and temperature due to mass transfer constraints on the oxygen reaction in the fixed bed electrode.