Electrolytic Sulfuric Acid Production with Carbon Mineralization for Permanent Carbon Dioxide Removal

Several billion metric tons per year of durable carbon dioxide removal (CDR) will be needed by mid-century to prevent catastrophic climate warming, and many new approaches must be rapidly scaled to ensure this target is met. Geologically permanent sequestration of carbon dioxide (CO2) in carbonate minerals—carbon mineralization—requires two moles of alkalinity and one mole of a CO2-reactive metal such as calcium or magnesium per mole of CO2 captured. Chemical weathering of geological materials can supply both ingredients, but weathering reactions must be accelerated to achieve targets for durable CDR. Here, a scalable CDR and mineralization process is reported in which water electrolysis is used to produce sulfuric acid for accelerated weathering, while a base is used to permanently sequester CO2 from air into carbonate minerals. The process can be integrated into existing extractive processes by reacting produced sulfuric acid with critical element feedstocks that neutralize acidity (e.g., rock phosphorus or ultramafic rock mine tailings), with calcium- and magnesium-bearing sulfate wastes electrolytically upcycled. The highest reported efficiency of electrolytic sulfuric acid production is achieved by maintaining catholyte feed conditions that minimize Faradaic losses by hydroxide permeation of the membrane-separated electrochemical cell. The industrial implementation of this process provides a pathway to gigaton-scale CO2 removal and sequestration during the production of critical elements needed for decarbonizing global energy infrastructure and feeding the world.