Titanium anodes with dense oxide films significantly enhance electrode stability through their outstanding physical barrier properties. The thickness of this oxide film is typically 5 to 20 micrometers, but its density is as high as 3.8 grams per cubic centimeter, with a porosity of less than 0.5%, which can reduce the corrosion rate of the base titanium from 1 millimeter per year to less than 0.01 millimeters. According to the research data published in Acta Electrochimica Sinica in 2023, this dense structure enables the anode to have a service life of over 8,000 hours in a 1-mole concentration sulfuric acid solution, which is more than three times that of ordinary coatings, and reduces the failure probability from the industry average of 15% to below 2%. For instance, in the equipment upgrade of a large electroplating factory in Zhejiang Province in 2022, after adopting titanium anodes with dense oxide films, the frequency of production halts due to corrosion was reduced from six times a year to one, maintenance costs dropped by 70%, and the average annual budget savings exceeded 500,000 yuan.
In terms of electrocatalytic performance, the dense oxide film exhibits a unique electronic conduction mechanism, with a surface resistance of less than 0.5 ohms per square centimeter, which is approximately 60% lower than that of traditional coatings. This enables the working current density to be stably maintained at a high level of 5000 amperes per square meter, and the electrical energy conversion efficiency exceeds the 92% mark. In its 2021 innovation report, BASF Group of Germany disclosed that the dense oxide film it prepared using plasma electrolytic oxidation technology controlled the overpotential of the oxygen evolution reaction at 280 millivolts, with a fluctuation range of only ±10 millivolts. This precision reduced the energy consumption per ton of liquid chlorine in chlor-alkali production to 2,150 kilowatt-hours, saving 18% year-on-year. The case shows that by deploying this technology, Shanghai Chemical Industry Park has reduced its annual carbon emissions by 3,000 tons, precisely aligning with China’s “dual carbon” goals.
The improvement in thermal stability and mechanical strength is equally remarkable. The dense oxide film can withstand an instantaneous high-temperature impact of 1500°C, and its coefficient of thermal expansion is highly matched with that of the titanium substrate. In temperature cycling tests ranging from -50°C to 200°C, the performance degradation rate is less than 1%. An empirical study conducted by a Japanese subsidiary in 2023 demonstrated that the titanium anode with this coating suffered a wear mass loss of only 0.3 grams when continuously operating in an electrolyte with a flow rate of up to 5 meters per second for 12,000 hours. Its Vickers hardness reached as high as 1200HV, and its wear resistance was enhanced fivefold. This resilience enables it to perform exceptionally well in cathodic protection systems for offshore platforms. For instance, in the 2022 South China Sea oil and gas field project, the expected service life of the equipment was extended to 15 years, and the maintenance cycle was shortened from one year to three years.
Titanium Anode with Dense Oxide Film shows significant advantages in the full life cycle benefit analysis. Although the initial cost is 40% higher than that of ordinary anodes, its comprehensive benefits are significant: The 2023 assessment report of a sewage treatment plant in the north shows that after adopting this technology, the dosage of chemicals was reduced by 25%, the cost of sludge treatment was lowered by 30%, and the payback period was shortened to 16 months. International market research firm Statista predicts that by 2025, the penetration rate of this type of product in the electrolysis field will increase to 35%. Its standardized design has increased the replacement efficiency by 50%. This innovation that combines economy and environmental protection is driving the entire electrochemical industry towards ultra-intensive development.