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A 2023 study reported that an organic amide catalyst used with carbon dioxide could drive chlorine production at high current density with low overpotential and high selectivity. The result points to a possible way to reduce electricity use in chlor-alkali electrolysis, but it is not evidence of commercial adoption: catalyst activity declined with use, and long-term durability in the chlorine-producing environment remains a central question.
Why chlor-alkali electrolysis uses so much electricity
Chlor-alkali electrolysis converts sodium chloride solution, or brine, into chlorine and sodium hydroxide (caustic soda). In a conventional membrane cell, chloride ions are oxidized at the anode to form chlorine. At the cathode, water is reduced to hydrogen and hydroxide; sodium ions cross the membrane and combine with hydroxide to make sodium hydroxide. The US EPA and ENERGY STAR guide identifies electrolysis as the most energy-intensive step in US chlor-alkali manufacturing.
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The 2023 study cites an estimate that the sector uses about 4% of global electricity, or roughly 150 TWh a year. These are estimates cited by the paper, not a newly measured global inventory. Because the process supplies chlorine and caustic soda used in many chemical products, even a modest efficiency improvement could matter at large scale.
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1Scan for outdated or missing drivers - takes under a minute2Clear out junk files and repair common Windows errors3Fix the driver behind crashes, sound loss and screen glitchesWhat the 2023 organic catalyst does
In “CO₂-mediated organocatalytic chlorine evolution under industrial conditions,” Yang and colleagues tested organic quinazoline-2,4-dione compounds, which contain an amide group, on a titanium-and-carbon electrode while bubbling carbon dioxide through the cell. The paper reports a current density of 10 kA m−2, 99.6% selectivity, and an overpotential of 89 mV for chlorine evolution under its experimental conditions. These are study results, not demonstrated performance across operating commercial plants. The Nature paper describes the catalyst system and its proposed mechanism.
#1 Best Overall
The proposed mechanism centers on reversible binding of CO₂ to the amide nitrogen. The researchers suggest this helps form a radical species involved in chlorine generation. In practical terms, the study explores whether a small organic molecule, aided by CO₂, can promote the anode reaction that releases chlorine.
Why the promising cell metrics do not settle the energy question
Current density, selectivity, and overpotential describe important aspects of an electrochemical cell, but they do not by themselves establish the electricity savings an industrial plant would achieve over years of operation. A catalyst must retain activity under operating conditions, and any comparison of total energy use needs a clearly stated system boundary and baseline.
Rank #2
- ⚡Coating composition :RUO₂+IRO₂+X
- ⚡Coating thickness :6~15um
- ⚡Current density :<3000A/㎡
- ⚡Voltage current: <15V/<10A
- ⚡Substrate thickness: high purity titanium 1mm (plate /mesh)
Chemistry World reported that the 2023 catalyst’s activity decayed with use and that the researchers thought its preparation might be improved. It also quoted Rolf Hempelmann of the University of Saarland on the operating environment: “Chlorine gas at oxidising electrochemical potential is the harshest chemical environment one can imagine.” Hempelmann assessed that the demonstrated construction could not compete with the roughly 10-year lifespan of existing systems; this is his assessment, not a verified lifespan for every plant. Chemistry World’s report also says the research team estimated that worldwide adoption might reduce the sector’s annual electricity use by approximately 1.8–4.6%. That is a conditional projection, not measured savings from commercial deployment.
A separate 2024 catalyst study
A different study, first published on January 5, 2024, tested an organocatalyst anchored on a single-atom support at both electrodes: for hydrogen evolution at the cathode and chlorine evolution at the anode. It reported overpotentials of 21 mV and 20 mV, respectively, at 10 mA cm−2, and energy consumption 1.2% below a commercial system under the study’s industrial conditions. The 2024 Angewandte Chemie International Edition study is a distinct design, not a replication or validation of the 2023 CO₂-mediated amide catalyst.
Rank #3
- Guaranteed edge leakage of less than 0.5% for maximum efficiency.
- Available in N324, N424, N438 thickness options to suit various needs.
- Withstands harsh chemical environments, pH range 0-14 for acids and alkalis.
- 50% higher tensile strength than standard membranes for enhanced durability.
- Easy installation with alkaline water pretreatment for reliable .
The studies should not be treated as a direct head-to-head comparison: they examine different catalyst designs and report different metrics and conditions. A 2024 review separately reports flow-cell results of 1,337 kWh per tonne of NaOH for an organocatalyst versus 1,402 kWh per tonne for a dimensionally stable anode, at 4 kA m−2 and higher. Those figures are a separate reporting layer and should not be attributed to the 2023 system or substituted for a common comparison of the two studies. The review discusses those results.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What remains uncertain
The key unresolved issue for the 2023 system is whether it can keep working in the harsh chlorine-evolving environment for industrially relevant periods. The cited sources do not establish whether it has since entered commercial deployment or undergone independent long-duration validation. The reported figures therefore show research promise, not proof that plants can yet replace existing anodes or realize the projected sector-wide savings.
Quick Recap
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- The electrolysis system using plate and frame configuration allows for the investigation of variables like temperature, material characteristics, electrode types, and fluid dynamics, making it suitable for applied research endeavors
- With an electrolysis reaction area of approximately 10 cm², the device comprises a circulation tank, electrode plates, and connecting pipelines
- This electrolytic cell utilizes graphite plates as well as interchangeable aluminum or copper plates as electrodes, maintaining a narrow 0.5 mm gap between poles
- The closely spaced electrodes within the electrolytic cell lead to a substantial reaction area, enabling swift electrolyte flow and reactions
- Warranty: StonyLab 1-year limited warranty; if received damaged, please contact us immediately; we will solve it until satisfied
Rank #4
- Guaranteed edge leakage of less than 0.5% for maximum efficiency.
- Available in N324, N424, N438 thickness options to suit various needs.
- Withstands harsh chemical environments, pH range 0-14 for acids and alkalis.
- 50% higher tensile strength than standard membranes for enhanced durability.
- Easy installation with alkaline water pretreatment for reliable .
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