I have been trying to convert chloride to perchlorate for about 6 months. I'm working at a 50mM level, while most of the literature I can find deals with saturated solutions. After months of optimization I have settled on a platinum anode and stainless steel cathode. I'm running the cell at 40 mA for one day and then boosting it to 100 mA. The potential varies, but is around 3V. I increase the pH to around 11 with NaOH, though I have not been buffering it. I've gotten 60% yield once, and have not been able to duplicate it. The electrochem prof. at my university suggests that I was pretty lucky to get a value that high.
I get 100% conversion of the chloride to chlorate overnight, but then the synthesis stalls and I typically max out at 40% yield. I have started trying to drive the oxidation further with chemical oxidants. Ammonium persulfate was ineffective and I am trying potassium permanganate as I type this. The chemistry is performed in a boiling water bath inside sealed vials.
I suspect that my problem is that I am preferencially oxidizing water and that none of my current is going towards the chlorate.
Any suggestions are appreciated, even if they seem inconsequential to you. I'm more a civil engineer by training with a microbiology focus during my phd, so chemistry is not second nature to me.