Novel process concept for the production of H₂ and H₂SO₄ by SO₂-depolarized electrolysis

Outotec open cycle (OOC) is a new low-energy process linking together production of hydrogen and sulfuric acid. While sulfuric acid is the world's most widely produced chemical by mass at approximately 200 Mt/a, the OOC gives the potential for making 4 Mt/a of hydrogen gas as a by-product. H₂SO₄ manufacture requires a source of sulfur dioxide. 30% of world production of H₂SO₄ is from the SO₂ by-product of pyrometallurgical processing of sulfur containing concentrates of metals such as copper, nickel and zinc. SO₂ can also be made by direct combustion of sulfur. In OOC, a divided electrochemical cell is used for SO₂-depolarized electrolysis of water. SO₂ is fed to the anolyte and converted to H₂SO₄, while hydrogen gas is produced at the cathode. On the industrial scale, the equipment will be in the form of a membrane electrolyzer assembly or stack. A case is described where the OOC would be connected to a pyrometallurgical plant smelting 1 Mt/a of nickel and copper concentrate, producing 1 Mt/a of H₂SO₄ and 20 kt/a of hydrogen.