Japan honours breakthrough in electrolyser stability

Asahi Kasei has received Japan’s prestigious Imperial Invention Prize for its development of a nickel-coated absorption layer that significantly extends the life of electrodes used in chlor-alkali electrolysis. The technology offers a novel solution to a long-standing challenge in industrial electrochemistry: preventing electrode degradation during operational shutdowns.
Used to produce chlorine, caustic soda, and hydrogen from brine, chlor-alkali electrolysis is a critical process for the chemical industry. However, temporary stops in operation - due to demand shifts or equipment issues - can trigger reverse current, accelerating cathode wear and raising energy costs. Traditional mechanical solutions are prone to failure and operator error.

Asahi Kasei’s innovation introduces a porous, nickel-coated absorption layer that reacts chemically during shutdown to block damaging reverse currents. The solution eliminates the need for mechanical components, enhancing system reliability and enabling long-term, stable operation.

The technology has already been commercialised, with widespread adoption by global chemical manufacturers. It was developed using thermal spraying, a coating technique that ensures both structural integrity and scalability across large electrode surfaces.

“This award is a strong endorsement of our commitment to advancing electrolysis technology,” said Akiyasu Funakawa, General Manager of Asahi Kasei’s Ion Exchange Membrane R&D Department. “Our goal is to deliver durable, efficient systems that support the sustainability of core chemical processes.”

Beyond chlor-alkali, Asahi Kasei is exploring how this breakthrough may benefit alkaline water electrolysis used in green hydrogen production - an area of growing interest across Asia’s clean energy landscape.

The award was presented by the Japan Institute of Invention and Innovation as part of the 2025 National Commendation for Invention.

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