SBIR Phase I: Dimensionally Stable Membrane for Chlor-Alkali Production

The Small Business Innovation Research (SBIR) Phase I project will develop a novel, Dimensionally Stable Ionomer Membrane (DSMTM) that offers high ionic conductivity, good ion exclusion capability, and excellent mechanical properties. The most advanced chlor-alkali electrolyzers utilize an ion-exchange membrane to separate the electrolysis solutions, but that membrane introduces inefficiencies due to the thickness required to survive and function within the electrolyzer. This research project deals with a new type of membrane utilizing a thin, laser-perforated support and incorporating carboxylic and sulfonic acid ionomers to simultaneously reduce the thickness of the membrane (and therefore the electrolyzer operating voltage) while maintaining functionality and improving durability. Just a few years ago, chlor-alkali electrolysis consumed 1.4% of all electricity generated in the United States; thus any improvement to electrolysis efficiency would result in significant power savings. The proposed research is expected to result in an electrolyzer voltage reduction of at least 125mV of the ~3.0V currently consumed, an energy consumption reduction of 4.2%.