The chemistry of hypochlorous acid
in the presence of metal impurities
is of high importance for many areas of chemistry ranging from water
purification and disinfection to sea water splitting and the electrosynthesis
of chlorate. The production of chlorate comprises one of the most
important electrochemical processes and relies on the Cr(VI) catalyzed
transformation of HOCl to chlorate. Since the use of Cr(VI) has been
restricted in the European Union due to its toxicity, mutagenicity,
and carcinogenicity, alternative catalysts need to be developed. Building
on the recently identified mechanism for the chromate catalyzed oxidation
of HOCl to chlorate, we performed a screening for potential alternative
catalysts using density functional theory modeling. Based on these
results, a volcano plot, which combines all previously reported reaction
paths, was constructed and the thermodynamic limitations were identified.
Our results indicate that, in principle, many materials are able to
catalyze the chlorate formation at much higher rates. However, in
practice, the reaction is limited by the strong correlation between
the pKa of the active site and the activity and the limitation to
pH neutral conditions. This renders chromate, despite its overall
poor performance, effectively the most active material. Furthermore,
we show that none of the remaining considered molecules is able to
replace Cr(VI) as the homogeneous catalyst due to side reactions or
process limitations. Thus, these results will have a significant impact
in the political decision of banning Cr(VI) in the chlorate process
and also clearly show that alternative approaches for chlorate synthesis
need to be developed if Cr(VI) is to be removed from the process.