Hydrochloric Acid Electrolysis

Efficient and Sustainable HCl-to-Chlorine Recovery

We turn waste Hydrochloric Acid into high-purity chlorine – cost-effective, energy-efficient and fully independent from volatile chlorine and hydrochloric acid markets. Reduce costs, cut CO₂ emissions by up to 30 %, and close your material loops in your production.

hydrochloric acid electrolysis plant

World-leading electrolysis technologies

1.5 GW/yr

supply chain established

>10 GW

of capacity installed

>3 GW

contracted capacity

Your Advantages at A Glance

Chlorine is used as an oxidizing agent in several organic processes and hydrogen chloride is often generated as a by-product or co-product. Instead of costly neutralization or disposal, our proven electrolysis technology recovers chlorine directly on-site, turning a waste stream into a valuable raw material. The recovery of chlorine from hydrogen chloride or hydrochloric acid has several advantages:

  • General commitment in terms of sustainability and therefore ecological responsibility.
  • Full independence from chlorine and hydrochloric acid prices.
  • Avoids the need to develop traditional chlor-alkali plants with significantly higher capital expenditure costs.
  • Interesting for regions with high chlorine demand or excess caustic soda (NaOH).
  • Up to 30 % lower energy consumption vs. conventional processes.
  • Significant reduction of chlorine transportation risks.
  • Compact design, low CAPEX and small plant footprint

Download Brochure

thyssenkrupp nucera hydrochloric acid electrolysis plant

Oxygen-Depolarized Cathode (HCl-ODC) Technology 

The gold standard for energy-efficient HCl electrolysis. ODC technology delivers up to 30% energy savings, eliminates hydrogen by-product formation, and offers flexible, reliable operation, making it ideal for MDI/TDI plants and projects focused on efficiency and carbon reduction.

More About HCl-ODC

Diaphragm Electrolyzer Technology

A proven and robust solution for hydrochloric acid electrolysis, developed in cooperation with Covestro. The diaphragm electrolyzer produces chlorine while generating valuable hydrogen as a by-product, making it the ideal choice for applications that require both high reliability and hydrogen utilization.

More About Diaphragm Electrolysis

Why Choose thyssenkrupp nucera

Energy savings up to 30 % (ODC)

Eliminates HCl neutralization and disposal costs

Compact footprint and fast project execution

Highest availability and easy capacity upgrades

From Concept to Lifetime Service Support

We deliver complete plants and support you throughout the entire lifecycle.

Explore Service Solutions

an employee of thyssenkrupp nucera in front of an electrolyzer

Get In Touch With Our Experts

Whether you’re planning a greenfield project, upgrading an existing plant, or exploring hybrid solutions – our team supports you with the right technology, engineering expertise, and service solutions. 

Contact Us

Frequently Asked Questions

How does HCl-to-chlorine recovery work?

HCl is split into chlorine and hydrogen (respectively water is formed in the ODC technology) via electrolysis in highly corrosion-resistant electrolyzers.
 

How much energy can I save?

Up to 30 % with ODC technology compared to conventional HCl electrolysis.

Is the technology suitable for MDI/TDI plants?

Yes, it was specifically optimized for isocyanate production and is operating in multiple large-scale plants.

What is the typical project timeline?

From kick-off to chlorine production approximately 24 months, depending on scope and local permits.