A new mononuclear Co(II) complex with the formula [Co(HL)2Cl2] (1) (HL= N-(2-hydroxy-1-naphthylidene)-2-methyl aniline) has been synthesized and characterized by Fourier transform infrared spectroscopy, UV–Vis, elemental analysis and single crystal X-ray structure analysis. Single crystals of the complex [Co(HL)2Cl2] (1) were obtained through slow evaporation of an acetonitrile solution at room temperature. The crystal structure analysis revealed that the two Schiff base ligands create a tetrahedral geometry via oxygen atoms and two chloride atoms. The nano-size of [Co(HL)2Cl2] (2) have been synthesized by the sonochemical process. Characterization of nanoparticles (2) was carried out via X-ray powder diffraction (XRD), scanning electron microscopy (SEM), UV-Vis, and FT-IR spectroscopy. The average sample size synthesized via the sonochemical method was approximately 56 nm. In this work, a simple sensor based on a glassy carbon electrode modified with [Co(HL)2Cl2] nano-complex was developed ([Co(HL)2Cl2] nano-complex/GCE) for convenient and fast electrochemical detection of butylated hydroxyanisole (BHA). The modified electrode offers considerably improved voltammetric sensitivity toward BHA compared to the bare electrode. Applying linear differential pulse voltammetry, a good linear relationship of the oxidation peak current with respect to concentrations of BHA across the range of 0.5–150 μM and a detection limit of 0.12 μM was achieved. The [Co(HL)2Cl2] nano-complex/GCE sensor was applied to the determination of BHA in real samples successfully.