Japanese technology leader Asahi Kasei has embarked on a collaborative demonstration project with Nobian, Furuya Metal, and Mastermelt, aiming to revolutionize resource management within the chlor-alkali industry. The initiative, which commenced in February 2025, focuses on establishing a comprehensive recycling ecosystem for valuable metals, including precious metals like iridium and ruthenium, extracted from end-of-life electrolyzer components used in caustic soda production.

For nearly half a century, Asahi Kasei has stood at the forefront of chlor-alkali electrolysis technology, supplying critical components such as ion-exchange membranes, electrolysis cells, and electrodes, alongside invaluable operational expertise. Electrolyzers play a pivotal role in splitting brine (saltwater) using electric current to yield essential chemicals like chlorine, hydrogen, and caustic soda, which serve as building blocks for a vast array of industrial and consumer products.

Recognizing the increasing global demand and strategic importance of precious metals like iridium and ruthenium, crucial materials in the production of high-performance electrodes and other electrolyzer components, Asahi Kasei has proactively sought partnerships to ensure a stable and sustainable supply chain. This new recycling project builds upon a prior collaborative effort with Nobian, a prominent manufacturer of caustic soda and other essential chemicals, which involved a European demonstration project for an electrolysis cell rental service initiated in 2023, emphasizing the reuse of precious metals.

This latest joint undertaking with Nobian, coupled with the specialized recycling expertise of Furuya Metal and Mastermelt, aims to create a closed-loop system within the chlor-alkali sector. The envisioned process will involve the efficient refining of valuable metals from electrolyzer cells and electrodes that have reached their operational lifespan, enabling their direct reuse as raw materials in the manufacturing of new components within the same industry. Notably, Asahi Kasei anticipates that the insights and processes developed through this initiative could also be extended to its electrolysis systems designed for green hydrogen production, leveraging clean energy sources.

The collaborative workflow of the demonstration project will see Asahi Kasei taking the initial step of collecting spent electrodes from Nobian’s facilities. These end-of-life components will then be transferred to recycling specialists Mastermelt and Furuya Metal. These companies will undertake the critical processes of removing the catalyst material from the electrodes, preparing it for subsequent treatment, and ultimately extracting and purifying the valuable precious metals contained within the catalyst.

In the final stage of this circular process, Asahi Kasei will utilize the recovered precious metals to formulate new catalyst materials. These recycled catalysts will then be applied to coat fresh electrodes, effectively reintegrating the reclaimed resources back into the production cycle. Nobian will then utilize these electrodes, featuring recycled catalytic materials, in their brine electrolysis processes, thus demonstrating a tangible pathway towards resource recycling in the production of caustic soda and chlorine.