hemical production via
electrolysis was not
piactical until the devel
opment of the electrical
dynamo in the 1870's.
Z. 1. Gramme, a Belgian
national working in
Trance, built the first central-station-
sized dynamo capable of continuous
operation, Significant technical contri-
butions by Weiner von Siemens in
Germany and Wenstrom in Sweden led
to a dynamo design in 1880 with the
fundamental fearures currently prac
ticed In the U.S., Edison patented a
dc. generator in 1879 capable of con
verting 80% of the applied horsepower
to electricity compared ta. Siemens
554, All these efforts were directed at
producing central station power tor
lectrie are lighting.{1) The result of
this activity was a massive power avall-
ability for commercial electrolysis, the
first major chemical industry in the
US.2)
Prior to this time, commercial eectro-
Unemisuy consisted of tro. areas:
galvanic cells and electroplating. Varia-
tions of Volta’s original voltaic pile
‘which consisted of alternating layers uf
copper and zinc interleaved with paste-
board soaked brine were commercially
available. Mlectroplating could be pow-
fered by one of these voltaic piles,
hand-cranked generators or by taking
advantage of replacement plating, n
1867, the Leclanche dry cell appeazed,
which was considerably more vonve:
nient. (1)
‘Niagara alls, NY, was a center for
the Hedghng electrolyue Industry i
the United States. In 1886, a syndicate
was granted authority to hamess up
to 200,000 hp of the How of the
Upper Niagara River. This dwarfed any
other eletiic project in the world
up until that time, The first contract
customers for the Niagara power were
the Pittsburgh Reduction Company
(ater Alcoa) for aluminum metal
production and Carborundum Compa
ny for making SiC electrothermally.
Both these projects were lured te
the Upper Niagara by the promise
of inexpensive power only. Later,
abundant salt deposits were dis.
covered and exploited by the fledgling
bleach, and chlov-alkalt industries. (1)
Other | mojor clectrolytic products
betore the turn of the century
included: bromine, sodium and potas-
sium. (2)
Electrolytic
Processing
by Richard D. Varjian
In the ensuing years, electrolytic
roures to a number of materials have
heen practiced commercially. These are
shown in Tabtt I. Most of the materials
are strong oxidizing or reducing agents,
for metals that are simply impractical t0
snnanulacture thermally. A few organic
chemicals have been manutactured
electrolytically beginning with manni-
tol and sorbitol in the tiid-1930'3.03,4)
‘Today, the major electrolytic products
arc aluminum, copper, chlorine and
soctiuim hydroxide, Tab I lists the
prominent electrolytic products, global
production rate and valuc.(6) Por
Comparison, ‘Tasie IML includes. non-
clectrolytic products. It is evident that
clectrolytic provesing. is somewhat
smaller in scale than other products of
the chemicals and metals industries (6)
‘he major electolytie products are
basic building, blocks of a variety of
Industrial, commercial and consumer
industries, and as such touch our lives
every day. Copper is the hase metal with
the greatest electrical conductivity and is
used in wire and electrical devices ofall
kinds. Aluminum is prized for its light
weight, corrosion. resistance and easy
formahility. Chlorine and sodium
Ihydioxide arc used widely in the chemi-
‘eal, petrochemical and paper industries.
Electrolytic manufacturing embodies
snany processes not mentioned in Tat
TL. These processes are practiced on a
smaller scale than those mentioned in
‘Taub, but they are ny Tess important
to those who employ them, Water elec-
trolysis to make high purity hydrogen
and oxygen is widely practived in
Furope A variety of organic chemicals
are produced electrochemically at the
rate of 100 tons per year.(/) Ihe largest
volume product of electro-arganic syn-
thesis Is adiponitile made by the
‘hydrodimerization of acrylonitrite. This
fs the well known Monsanto process
first demonstrated by Manuel Baizet in
the laboratory and later improved by
Don Danly. (12) Production is estimat-
ced at 300,000 tons per year. (7) The
electrorefining, of metal oxidizes
{impure metal for re-