This paper describes a numerical analysis of the melting process of gelled crude oil in water for hydrogen production. The melting characteristics of crude oil particles are analyzed, and the influence of flow velocity, particle radius, and hot water temperature on the melting process is discussed. The results indicate that the melting rate on the surface of the crude oil is different, the oil particles do not melt concentrically, and the monitoring points and rate of increase in temperature are not substantially affected by the phase change interval. The flow rate and particle radius are found to have a significant influence on the phase distribution of the oil droplets, but changes in water temperature have little effect. After validating a model of the melting process, we investigate the influence of oil particle size, water temperature, flow rate, and oil temperature. It is found that increases in water temperature and flow rate, or a decrease in oil particle size, tend to reduce the melting time. (C) 2018 Published by Elsevier Ltd on behalf of Hydrogen Energy Publications LLC.