CHLOR-ALKALI COATINGS

AND
REFURBISHMENT SERVICES

By Dr Derek C Armstrong

KEY FACTS

INEOS manufactures all its own coatings

All INEOS coatings can be tailored to customers membrane cycles

Anodes
Cathodes

8, 10, 12 years
8, 10, 12, 15, 16 years

INEOS coatings are currently installed in the following electrolysers

INEOS
UHDE
AK
MGC
INEOS HAS BEEN MANUFACTURING CHLOR ALKALI ELECTRODES FOR 118 YEARS

INEOS ANODE COATINGS

Anode Coatings

A layer of conductive, catalytic material applied to the surface of a
titanium anode to promote chlorine evolution at low voltage

Applied in layers followed by stoving (thermal decomposition)

Key components are RuO2, IrO2

Voltage performance dependent on
surface area

Surface shows a cracked structure

Lost by 2 mechanisms

Mechanical loss

Alkaline wear
SEM of INEOS anode coating 1.5K magnification

Anode Coatings Features to consider in Coating Selection

Feature

What is it?

Impact ?

Over-potential

Additional voltage generated

Higher over potentials mean higher
by the surface resistance of the power consumption- adds to operating
coating
cost

Alkali Wear
Resistance

Resistance to loss of
Ruthenium, the critical catalytic
element, during operation

High alkali wear = short anode life, or

more expensive anodes as suppliers
add more RuO2

High Chlorate in
brine

ClO3- is produced as a by
product of Cl2 production

Potentially environmentally damaging

and discharge may be limited
Higher chemical usage in chlorate
destruction system
Higher rates of corrosion in caustic
evaporators as higher levels of chlorate
in caustic soda.

INEOS Anode Coating LOW CHLORINE OVER POTENTIAL

Chlorine over-voltage
chlorine over-voltage (mV)

60
55
50
45
40

INEOS ANODE COATING

TYPICAL COMMERCIAL ANODE COATING

35
30
25
20
0

Time

INEOS ANODE coatings have been designed to provide a chlorine overvoltage of 20-30mV lower than typical commercial coatings. This represents a
1% power saving for customers (eg based on $80 per MWh a 100kte plant
would save $120k/year)
6

INEOS Anode Coating LOW ALKALINE WEAR

Accelerated Alkaline Wear Test - Voltage Rise - 20kA/m2 Current Density
9
8

Standard
Com
petitor
Commercial
coating

CP304
INEOS
7

Voltage ( V )

6
5
4
3
2
1
0
0

10

20

30

40

50

60

Time

70

80

90

100

110

120

130

140

Duration (Hours)

INEOS ANODE coatings have been designed to provide significantly superior alkaline
wear performance over other commercially available chlor-alkali anode coatings.
With the move to zero gap where the membrane lies directly up against the membrane
good alkaline wear resistance in very important for coating life as the surface of the
membrane is alkaline.

INEOS Anode Coating LOW CHLORATE IN BRINE

INEOS

Competitor

Chlorate (g/l)

0.05

0.3

Hypochlorite (g/l)

0.8

1.5

INEOS ANODE coatings have been designed to provide a very low level of
chlorate (and hypochlorite) in brine.
This translates to less chemical usage for chlorate destruction but more
importantly lower chlorate in caustic, stopping evaporator corrosion.

INEOS CATHODE COATINGS

Cathode Coatings

A layer of conductive, catalytic material applied to the surface of a cathode to promote hydrogen
evolution at low voltage.

Key components are many and vary dependent upon the supplier.
e.g. RuO2, Raney nickel, Pt group metal oxides, Nickel Oxides, sulfides, carbides.

Applied using a range of techniques depending upon the coating type.

e.g. spray-bake, electro deposition, plasma spray, electroless plating, catholyte additive.

Total coating thickness 200microns to

>1 micron depending upon type.

Best have a high ratio of catalytic area

to apparent area.

Loss mechanisms are

Wear
Reverse current dissolution
poisoning
SEM of INEOS cathode coating 4K magnification

10

Typical Progression of Cathode Coating Wear

100

INEOS precious metal coating

coating

% of starting catalyst remaining in

Cathode coating loading vs time on load - schematic

Non-precious metal coating

0
0
time on load

Non-precious metal coatings normally last 4-8 years

INEOS precious metal coating shows virtually no loss (warrantied for 16 years)

>18 years experience in our FM mono-polar technology

13 years experience on BICHLOR with no measurable loss

11

High resistance to reverse currents

Accelerated Cathode Durability Data
85C 32% NaOH (Data HF Resistance Corrected)

0.000

E(V) verus RHE

-0.050
-0.100
-0.150
-0.200

Coating totally failed

-0.250
-0.300
-0.350
0

100

200

300

400

500

600

700

800

Test Cycles
INEOS cathode coating

Non precious
metalcoating
cathode coating
Competitor
cathode

The INEOS CATHODE Coating has an exceptionally high resistance to

reverse currents making it the ideal cathode coating for all zero gap
electrolysers.

12

Features of INEOS Cathode Coatings in summary

Feature

INEOS vs Competitor

Over potential

In trials in other technologies INEOS over potential at start-up is the

same as non precious metal coatings but demonstrates better
performance over a longer lifecycle.

Resistance to
INEOS cathode coatings lose no catalyst when subjected to reverse
reverse currents at current..
shutdown
Non precious metal coatings are known to be attacked by reverse
currents
Resistance to
impurity poisoning

High surface area minimises the sensitivity to impurity damage.

Any poisoning that does occur tends to be reversible (e.g. at
shutdown)

Lifetime

13

Experience indicates INEOS cathode coatings will last for >16 years
Proven in FM mono-polar electrolysers over 18 years,
13 years (and counting) without weight loss in BICHLOR bipolar
electrolysers

INEOS REFURBISHMENT CAPABILITY

14

INEOS Refurbishment Facility

A new purpose built facility commissioned in Q1 2013.

First delivery within 4 weeks from initial receipt of pans.

Smaller batches can be accommodated in a shorter lead time.

In addition to modular type electrolysers, different types of structures may be processed for
example mercury and large fly screen meshes.

15

Refurbishment Process

Receipt and identification

Pre-work inspection & assessment (Recorded in database)

Refurbishment - Repair (Mesh, Flange and Pan repair)

Surface preparation

Coating

Final quality inspection

Packing & Dispatch

16

Inspection

17

Expert Welding

Fine jewellery
type welding by
experts

18

Refurbishment Flange and electrode damage/corrosion

flange corrosion

Corrosion at compression points

19

crevice corrosion

Corrosion of louver

Louvre Replacement

Sections of corroded louvre

are removed and replaced

20

Inlet Repair

Corrosion to outlet pipe

21

Inlet Repair

Completed Repair

22

Key Steps Surface Preparation

ANODE

CATHODE

23

Pan/Element Washing

24

In-Pan/Element Coating

25

In-Pan/Element Coating

Flange protected by coating

26

Final Inspection

27

Finished Product Preparing for Shipment

28

SUMMARY
INEOS CAN PROVIDE : STATE OF THE ART COATINGS
Long life
Robust against wear, reverse currents and impurities
Low over voltage
 COMPREHENSIVE RE-COATING AND REFURBISHMENT SERVICE