The key interface component between the reactor and chemical systems for the sulfuric acid based processes to make hydrogen is the sulfuric acid decomposition reactor. The materials issues for the decomposition reactor are severe since sulfuric acid must be heated, vaporized and decomposed. SiC has been identified and proven by others to be an acceptable material. However, SiC has a significant design issue when it must be interfaced with metals for connection to the remainder of the process. Westinghouse has developed a design utilizing SiC for the high temperature portions of the reactor that are in contact with the sulfuric acid and polymeric coated steel for low temperature portions. This design is expected to have a reasonable cost for an operating lifetime of 20 years. It can be readily maintained in the field, and is transportable by truck (maximum OD is 4.5 meters). This paper summarizes the detailed engineering design of the Westinghouse Decomposition Reactor and the decomposition reactor’s capital cost.

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