The modernization project, co-financed by the Portuguese Recovery and Resilience Plan, installed nine chlor-alkali electrolyzers at Bondalti’s Estarreja site. These units separate brine (concentrated salt water) into chlorine, caustic soda, and hydrogen, which serve as key feedstocks for a wide range of chemical products across multiple industries. One electrolyzer will also be used for trial runs with new components to further improve environmental performance, including energy reduction and resource optimization.
The electrolyzers incorporate Asahi Kasei’s latest ion exchange membranes and advanced electrodes, delivering improved operational efficiency compared to conventional systems. Used cells and electrodes from the trials will be recycled, supporting Asahi Kasei’s circular economy approach within the chlor-alkali sector.
David Lopes, Director of Bondalti, said: “The start-up of our new, state-of-the-art chlor-alkali plant was made possible by the expertise of our partners and the dedication and skills of our people. This achievement marks a strategic milestone in Bondalti’s commitment to sustainable innovation and operational excellence and strengthens our vision of leading the way in responsible chemical manufacturing.”
Asahi Kasei combines five decades of experience in the development, manufacturing, and operation of electrolysis systems with operational monitoring and software analysis services through its Canadian subsidiary, Recherche 2000. The company also recently established a metal recycling ecosystem to support sustainability in electrolyzer operations. Its comprehensive offerings include ion-exchange membranes, electrolysis cells, electrodes, and operational expertise for chlor-alkali plants worldwide.
The upgraded facility at Estarreja represents a significant step in Bondalti’s strategy to meet tightening EU decarbonization regulations while maintaining high reliability and efficiency in chemical production. By integrating advanced technology and sustainability practices, the company seeks to optimize power usage, reduce environmental impact, and maintain leadership in responsible chemical manufacturing.
Overall, the new plant demonstrates how collaboration between engineering firms and technology providers can advance operational excellence, environmental performance, and the adoption of circular economy principles within the chemical industry. With the modernized chlor-alkali facility, Bondalti strengthens its commitment to innovation, sustainability, and industrial efficiency.
