HYPOCHLOROUS ACID PROCESS

The invention is concerned with an improved process for producing hypochlorous acid by reacting an aqueous solution of an alkali metal hydroxide in droplet form with gaseous chlorine to produce hypochlorous acid vapor and solid alkali metal chloride particles, in which the improvement comprises employing molar ratios of gaseous chlorine to the alkali metal hydroxide of greater than about 20:1. The process according to the invention achieves high yields of hypochlorous acid by minimizing side reactions including the formation of chlorate as an impurity in the alkali metal chloride particles produced. In addition, the process produces solid alkali metal chloride particles having low concentrations of moisture thus reducing scaling or reactor surfaces and improving salt recovery.