The electrolysis of cuprous chloride was carried out in the electrochemical cell. The particle size, current density, cathodic current efficiency, conversion of cuprous chloride and yield of copper formed depends strongly on current flow, heat transfer and mass transfer operation. The current flow, heat transfer and mass transfer are depends on surface area ratio of anode to cathode, distance between electrodes, concentration of HCl, applied voltage, flow rate of electrolyte, CuCl concentration and reaction temperature. The electrolysis of cuprous chloride as a part of Cu—Cl thermochemical cycle for hydrogen production is experimentally demonstrated in proof-of-concept work.