The chlor-alkali process is an essential industrial method for producing three primary chemicals: chlorine (Cl₂), sodium hydroxide (NaOH, also called caustic soda), and hydrogen (H₂). These products are foundational to a wide range of industries, including chemicals, paper, textiles, water treatment, and pharmaceuticals.
This process typically involves the electrolysis of a sodium chloride (NaCl) brine solution. Through the application of electricity, chlorine gas is generated at the anode, while sodium hydroxide and hydrogen gas are produced at the cathode. The reactions are conducted in specialized electrolytic cells—mercury cells, diaphragm cells, or modern membrane cells—each with different efficiencies, environmental impacts, and cost considerations.
The chlor-alkali process is energy-intensive, consuming significant electricity, which is why advancements in energy efficiency are a constant focus for manufacturers. Given the importance of chlorine and caustic soda in disinfectants, PVC manufacturing, food processing, and pulp production, the chlor-alkali industry remains a crucial pillar of global manufacturing.