The new generation of ion-exchange membrane chlor-alkali plants (2024–2030 generation) is delivering 25–35% more energy-efficient operations thanks to advances like higher current densities and oxygen-depolarized cathode (ODC) designs. However, this shift dramatically changes the risk profile, as higher current densities, thinner membranes, and increased automation amplify certain loss scenarios that were previously negligible. This description breaks down the leading hazards for new-build membrane plants. We detail the Top Eight Emerging Major Accident Hazards (MAH), including the risks of massive hydrogen-in-chlorine crossover leading to cell-room explosion, thermal runaway due to brine depletion, and cyber intrusion causing rectifier overload. Finally, we summarize the best-practice mitigation benchmarks—such as independent low-low brine flow trips and redundant online moisture analyzers—that owners and insurers recognize, which can materially improve safety, reduce risk, and help cap Maximum Foreseeable Loss (MFL) scenarios below US$450 million.
