A 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 at least about 22:1. The process 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. The hypochlorous acid solution produced contains from about 35 to about 60 percent by weight of HOCl, a dissolved chlorine concentration of less than about 2 percent by weight, and is substantially free of alkali metal ions and chloride ions.