Bearing the aim of carbon neutrality in mind, we, Hefei Sinopower Technologies Co., Ltd, devote ourselves to the promotion and application of clean energy technologies and products.
Blog
Hefei Sinopower Technologies Co., Ltd
Email:
Fax:
WhatsApp:
Cathode Gap Adjustment of Chlor-alkali Electrolyzer: A "precision surgery" for existing equipment, rapidly reducing costs and increasing efficiency.
Release time:
2025-12-05
In the complex system of chlor-alkali production via the ion-exchange membrane electrolysis process, cell voltage is the core determinant of plant energy costs. The cell voltage (V_cell) primarily consists of the theoretical decomposition voltage, electrode overpotential, membrane voltage drop, and ohmic voltage drop. Among these, the ohmic voltage drop is directly related to electrolyte resistance, membrane resistance, and electrode gap, with the influence of the latter often severely underestimated.
The essence of electrode gap modification lies in precisely adjusting the cathode/anode systems of an operating electrolyzer at millimeter or even sub-millimeter levels to shorten the physical distance between electrodes. This directly reduces the ohmic resistance that the current must overcome as it flows through the electrolyte.
This "surgical" intervention aims to address the following critical issues:
Directly Tackling "Millivolt Waste":
According to Ohm's law in electrolyzers, under a constant current, any reduction in resistance translates directly and linearly into a voltage drop. For every 1 mm reduction in electrode gap, the corresponding decrease in cell voltage (on the order of millivolts) is specific and calculable. In a modern plant operating at currents as high as several hundred kiloamperes, a seemingly minor voltage drop of tens of millivolts results in a dramatic reduction in power loss.
Unlocking the Potential Capacity and Energy Efficiency of the Unit:
Under the condition of an unchanged power supply capacity, a reduction in voltage equates to a decrease in the direct current consumption per unit of product (kWh/ton of caustic soda), representing the most direct improvement in energy efficiency. Simultaneously, the "headroom" saved in voltage can be leveraged in two optimization pathways:
Energy-saving mode: Maintain current production while significantly reducing total energy consumption.
Efficiency-enhancing mode: Within the total voltage limit, allow for an appropriate increase in current density to boost output, thereby raising the productivity per unit of asset.
Addressing Performance Degradation from Long-term Operation:
After prolonged operation, factors such as changes in electrode coating activity, slight membrane deformation, micro-displacements of components, or scaling may cause the actual operating electrode gap to deviate from the original optimal design value. Electrode gap modification is not merely about "reducing the distance." Instead, based on detailed voltage analysis and internal diagnostics, it involves "calibrating" the electrode gap of each electrolyzer to a personalized optimal value under the current state of the membrane and electrodes. This represents a targeted performance restoration and re-engineering.
Laying the Foundation for Comprehensive Upgrades:
Successful electrode gap modification not only delivers immediate energy-saving benefits but also creates conditions for subsequent deeper technical upgrades, such as adopting new high-activity coated electrodes or thinner, low-resistance ion-exchange membranes. This is because a shorter electrode gap synergizes with more advanced electrode and membrane technologies, maximizing the return on investment for each upgrade.
Cathode Gap Adjustment of Chlor-alkali Electrolyzer is far from a simple mechanical adjustment; it is an in-depth optimization technology integrating electrochemistry, materials mechanics, and precision engineering. By performing a "minimally invasive" and "precision intervention" with the shortest possible downtime on existing core units, it directly acts on a key variable in the energy consumption equation. As such, it stands as one of the most direct and efficient "leverage points" for chlor-alkali plants to reduce costs, improve efficiency, and enhance competitiveness. In today's environment of high energy costs, this technology has become a standard choice for leading chlor-alkali enterprises striving for operational excellence.
Cathode Gap Adjustment of Chlor-alkali Electrolyzer,Chlor-alkali Electrolyzer,Chlor-alkali Electrolyzer Cathode Gap Adjustment,Chlor-alkali Production,Cathode Gap maintenance & commissioning,Electrolyzer Cathode Gap calibration service
Service Hotline
Mobile site
© COPYRIGHT 2022 Hefei Sinopower Technologies Co.,Ltd.