This paper investigates the heat transfer and X-ray diffraction patterns of solidified molten salt droplets in heat recovery processes of a thermochemical Cu-Cl cycle of hydrogen production. It is essential to recover the heat of the molten salt to enhance the overall thermal efficiency of the copper-chlorine cycle. A major portion of heat recovery within the cycle can be achieved by cooling and solidifying the molten salt exiting an oxygen reactor. Heat recovery from the molten salt is achieved by dispersing the molten stream into droplets. In this paper, an analytical study and experimental investigation of the thermal phenomena of a falling droplet quenched into water is presented, involving the droplet surface temperature during descent and resulting composition change in the quench process. The results show that it is feasible to quench the molten salt droplets for an efficient heat recovery process without introducing any material imbalance for the overall cycle integration. (C) 2015 Elsevier Ltd. All rights reserved.