Alternative hydrogen production methods are being explored with the goal of finding efficient and economical process. The copper-chlorine (Cu-Cl) cycle for hydrogen production has been the focus of the Clean Energy Research Laboratory (CERL) at the University of Ontario Institute of Technology (UOIT). The Cu-Cl cycle has lower thermal energy requirements compared to other methods and utilizes waste heat from power plants and/or industrial processes. The cycle is comprised of the electrolysis, hydrolysis and thermolysis reaction steps. Decomposition of copper oxychloride (CuOCuCl2) occurs in the thermolysis reactor at 500-530 degrees C. A novel thermolysis reactor design is presented here with the purpose of scaling it up to a pilot at an industrial site. Using a dual heater configuration, simulations showed decomposition temperatures were achieved between 3.5 and 4 h with 2.0 kg of CuCl as the feedstock. With 10 kg of CuCl, the reactor would reach decomposition temperatures after 10 h of heat up. Improved start-up thermal performance was observed during experiments with solidified CuCl and a reduction of startup time. (C) 2018 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.