Production of chlorine dioxide in an electrolytic cell

Claim 2

An electrolytic process for the production of chlorine dioxide, which comprises: providing an electrolytic cell having a cathode compartment with a three-dimensional high surface-area cathode therein and an anode compartment separated from the cathode compartment by a cation-exchange membrane, feeding chlorate ions to the cathode compartment and providing hydrogen ions and chloride ions in said cathode compartment, reducing said chlorate ions with said hydrogen ions and chloride ions in said cathode compartment to form chlorine dioxide while an electric current is applied to the cathode compartment to reduce chlorine co-produced with said chlorine dioxide to chloride ions, venting chlorine dioxide so produced, and electrolytically forming hydrogen ions in said anode compartment and transferring said hydrogen ions across said cation exchange membrane from said anode compartment to said cathode compartment.

Claim 3

The process of claim 1 wherein said hydrogen ions and chloride ions in said cathode compartment are provided in part by said hydrogen ions transferred to said cathode compartment from said anode compartment and by said chloride ions produced by electrolytic reduction of said co-produced chlorine, and in part by hydrogen ions and chloride ions fed to said cathode compartment from external sources.

Claim 4

The process of claim 2 wherein said external source hydrogen ions and chloride ions are provided by hydrochloric acid.

Claim 5

The process of claim 1 wherein said hydrogen ions and chloride ions in said cathode compartment are provided, for hydrogen ions, wholly by said hydrogen ions transferred to said cathode compartment from said anode compartment and, for chloride ions, in part by said chloride ions produced by electrolytic reduction of said co-produced chlorine and in part by chloride ions produced by electrolytic reduction of chlorine fed to said cathode compartment from an external source.

Claim 6

The process of claim 1 wherein said cathode compartment has a sodium chlorate concentration of at least about 5 molar and a total acid normality of at least about 0.01N.

Claim 7

The process of claim 1 wherein an eleotrode potential is applied to the cathode which is more positive than -1 volt as compared with a saturated calomel electrode and as determined at the current feeder to the three-dimensional cathode and more negative than the open circuit potential under the prevailing conditions.

Claim 8

The process of claim 6 wherein said cathode comprises stacked layers of electroconductive mesh material through the interstices of which percolates the chlorate solution generally parallel to the current flow.

Claim 9

The process of claim 6 wherein said cathode comprises a packed bed of individual electroconductive particles through which percolates the chlorate solution generally perpendicular to the current flow.

Claim 10

The process of claim 6 wherein said cathode is constructed of a material having a high overpotential for the reaction Cl 2 →Cl - .

Claim 11

The process of claim 9 wherein said high overpotential electrode material is graphite or other carbonaceous material.

Claim 12

A continuous electrolytic process for the production of chlorine dioxide, which comprises: continuously feeding aqueous sodium chlorate solution to a cathode compartment of an electrolytic cell wherein the cathode compartment is provided with a three-dimensional high surface-area cathode therein and is separated from an anode compartment by a cation-exchange membrane, continuously reducing said sodium chlorate in said cathode compartment with hydrogen ions and chloride ions to form chlorine dioxide and chlorine in accordance with the equation: NaClO.sub.3 +2H.sup.+ +2Cl.sup.- →ClO.sub.2 +1/2Cl.sub.2 +H.sub.2 O+NaCl while an electric current is applied between the anode and cathode compartments, continuously electrolytically reducing said chlorine co-produced with said chlorine dioxide to chloride ions in said cathode compartment to provide part of the chloride ions used in said reduction of sodium chlorate, continuously electrolytically forming hydrogen ions from an electrolyte in said anode compartment and transferring said electrolytically-formed hydrogen ions from said anode compartment to said cathode compartment to provide at least part of the hydrogen ions used in said reduction of sodium chlorate, continuously providing the balance of hydrogen ions and chloride ions used in said reduction of sodium chlorate in said cathode compartment, continuously venting chlorine dioxide so produced, and continuously removing a by-product stream of sodium chloride solution from said cathode compartment.

Claim 13

A continuous electrolytic process for the production of chlorine dioxide, which comprises: continuously feeding aqueous sodium chlorate solution to a cathode compartment of an electrolytic cell wherein the cathode compartment is provided with a three-dimensional high surface-area cathode therein and is separated from an anode compartment by a cation-exchange membrane, continuously reducing said sodium chlorate in said cathode compartment with hydrogen ions and chloride ions to form chlorine dioxide and chlorine in accordance with the equation: NaClO.sub.3 +2H.sup.+ +2Cl.sup.- →ClO.sub.2 +1/2Cl.sub.2 +H.sub.2 O+NaCl while an electric current is applied between the anode and cathode compartments, continuously electrolytically reducing said chlorine co-produced with said chlorine dioxide to chloride ions in said cathode compartment to provide part of the chloride ions used in said reduction of sodium chlorate, continuously electrolytically forming hydrogen ions from an electrolyte in said anode compartment and transferring said electrolytically-formed hydrogen ions from said anode compartment to said cathode compartment to provide at least part of the hydrogen ions used in said reduction of sodium chlorate, continuously providing the balance of hydrogen ions and chloride ions used in said reduction of sodium chlorate in said cathode compartment, continuously venting chlorine dioxide so produced, and continuously removing a by-product stream of sodium chloride solution from said cathode compartment.

Claim 14

The process of claim 11, wherein about 1 Faraday of electrical current is applied to the cell per mole of chlorine dioxide produced, whereby said electrolytically-reduced chlorine and said hydrogen ions transferred from said anode compartment provide approximately one half of the molar quantity of said hydrogen ions and chloride ions used in said reduction of sodium chlorate, and the remainder of the molar quantity of said hydrogen ions and chloride ions used in said reduction of sodium chlorate is provided continuously by hydrogen ions and chloride ions from sources external of said cathode compartment.

Claim 15

The process of claim 12 wherein said external sources of hydrogen ions and chloride ions are provided by hydrochloric acid.

Claim 16

The process of claim 11, wherein about 2 Faradays of electrical current are applied to the cell per mole of chlorine dioxide produced, whereby said hydrogen ions transferred from said anode compartment provide substantially all of the molar quantity of said hydrogen ions and said electrically reduced chlorine provides approximately one-half of the molar quantity of said chloride ions used in said reduction of sodium chlorate, and the remainder of the molar quantity of said chloride ions used in said reduction of sodium chlorate is provided by feeding chlorine continuously from an external source to said cathode compartment and electrolytically reducing said chlorine to said remainder of aid chloride ions.

Claim 17

The process of claim 11, wherein said catholyte has a chlorate concentration of about 5 to about 6.5 molar, a chlorate to chloride ion ratio of about 2:1 to about 4:1, a total acid normality of at least about 0.05 normal, and a temperature of at least abut 50° C.

Claim 18

The process of claim 15 wherein said temperature is about 60° C. to about 70° C.

Claim 19

The process of claim 14 which is integrated with a sodium chlorite-producing electrolytic process wherein said chlorine dioxide is electrolytically reduced to chlorite ions, chlorine is electrolytically formed and is forwarded to said cathode compartment to provide said chlorine feed thereto.

Claim 20

The process of claim 17 which is further integrated with a sodium chlorate-producing electrolytic process wherein by-product sodium chloride from said cathode compartment is electrolyzed to provide said sodium chlorate feed to said cathode compartment.

Claim 21

The process of claim 14 which is integrated with a caustic-chlorine cell wherein by-product sodium chloride from said cathode compartment is electrolyzed to provide said chlorine feed to said cathode compartment.

Claim 22

The process of claim 11 wherein an electrode potential is applied to the cathode which is more positive than -1 volt as compared with a saturated calomel electrode and as determined at the current feeder to the three-dimensional electrode and more negative than the open circuit potential under the prevailing conditions.