Reactor Parameters Research Articles

Hydrogen generation through metal waste corrosion: a systematic investigation on old/post-consumer scrap Al6063-series alloy

In this study, aluminum-based wastes are used as energy carriers for on-demand hydrogen production through sustainable, eco-friendly, and cost-effective controlled electrochemical corrosion in aqueous solution. The electrochemical process is very effective because it (i) uses waste metals to produce hydrogen, (ii) corroborates to circular economy, (iii) produces high purity hydrogen, (iv) is based on simple hydrolysis reaction of metals in relevant solutions, (v) electricity is not required and (iv) recovers part of the chemical Gibbs energy of the electrochemical corrosion usually entirely lost in the environment. We systematically studied the generation of hydrogen from industrial waste Dust Scrap Aluminum Alloy (DSAA) belonging to Al 6063 series for the first time. The process is investigated in a novel hand-made batch reactor with a low-cost commercial body suitable to an easy scale-up. Kinetics of DSAA hydrolysis reaction was explored by measuring the variation of aluminium ion concentration at different immersion times through Inductively Coupled Plasma (ICP) and weight loss measurements at different temperatures and NaOH catalyst concentrations. The effect of hydrolysis reaction on the composition and morphology of the metal surfaces in terms of formed oxide layers was studied in detail using Optical Polarizing Microscopy (OPM), Energy dispersive X-ray (EDX) and Scanning Electron Microscopy (SEM) techniques. The criteria used to evaluate the hydrogen reactor performance were hydrogen (i) yield and (ii) production rate. The experimental results showed that a strong increase in NaOH concentration (from 0.75 to 5 M) corresponding to a slow increase in hydrolysis reaction temperature (from 38.8 to 49.9 °C) lead to an improvement in hydrogen generation rate of one order of magnitude, i.e. from 35.71 to 421.41 ml/(g∙min). Low but constant rate of hydrogen can be generated for longer times at low NaOH concentrations (0.75 M), while fast and variable hydrogen generation rate occurs at higher concentrations (5 M) in short times. In the case study of Al 6063 series waste scrap, the hydrolysis reactor parameters can be regulated to deliver hydrogen generation rates from 35.71 to 421.41 ml/(g min) according to requirements. We expect that the results presented in this work will encourage researchers to study the possible use of other metal-based and multi-material plastic/metal wastes thermodynamically prone to electrochemical corrosion process as possible source of hydrogen.Graphical

Scale-up of Microdroplet Reactors for Efficient CO2 Resource Utilization.

Two-phase reactions involving microdroplets have gained significant attention in recent years due to their unique ability to catalyze and accelerate reactions that typically do not occur under standard conditions by leveraging chemical and physical effects at the micrometer-scale interface. In this work we have innovatively developed a scaled-up microdroplet reactor for the efficient resource utilization of CO2. The reaction liquid is sprayed in the form of mist (d32 < 20 μm), facilitating complete contact and reaction with gaseous CO2. We explored the effects of spray properties and reactor parameters on the continuous production of organic carbonates from CO2. Remarkably, the microdroplet reactor enhanced the reaction efficiency by at least 10-fold compared to conventional high-pressure reactor setups. Additionally, we used computational fluid dynamics (CFD) simulations to optimize the process conditions and continuous production parameters, systematically studying the effects of scaling up the device. Here, we present insights into the utilization of microdroplet reactors for CO2 conversion in scaled-up applications, supported by robust data.

Utilization of Cocoa Pod Husk Waste as Fuel for Downdraft Type Gasification Reactor of 960 Liters Capacity in Berau Regency

This experiment aims to investigate the performance characteristics of a downdraft gasification reactor fueled by cocoa pod husk as a technological solution for obtaining alternative renewable energy sources to replace fossil fuels and natural gas. The research was conducted experimentally on a gasification reactor made of SS310 thermal resistant carbon steel material. The reactor has dimensions of 35 centimeter in diameter and 250 centimeter in height. Measurement of gasification zone using 7 units of K-type thermocouples that was installed along the reactor wall. Fuel was feeding continuously at a rate of 4kg/hour. The research was conducted by varying the temperature in oxidation zone, specifically at 900 ºC, 950 ºC, 1000 ºC, 1050 ºC, and 1100 ºC. Data collection was carried out in different temperature variations and processed to determine the performance parameters of the gasification reactor, including gas composition, temperature distribution on the reactor wall, and the lower heating value (LHV) of the syngas production. The results showed the highest temperature distribution of the reactor in the drying zone 205ºC, pyrolysis zone 575ºC and reduction zone 520 ºC that be obtained at the oxidation temperature of 1100 ºC . Meanwhile the optimum value of syngas quality was obtained at the oxidation temperature of 1000 ºC with the composition of flamable syngas CO, H2, and CH4 are 27.08%, 8.53% and 2.41% , with the highest LHV 5206 kJ/m3. In general the increasing of the oxidation temperature lead to a positive contribution to the performance of the gasification reactor using cocoa pod husk waste.

Heterogeneous reactions in a HFCVD reactor: simulation using a 2D model

In this study, a simulation of the elementary chemical reactions during SiOx film growth in a hot filament chemical vapor deposition (HFCVD) reactor was carried out using a 2D model. For the 2D simulation, the continuity, momentum, heat, and diffusion equations were solved numerically by the software COMSOL Multiphysics based on the finite element method. The model allowed for the simulation of the key parameters of the HFCVD reactor. Also, a thermochemical study of the heterogeneous reaction between the precursors quartz and hydrogen was carried out. The obtained equilibrium constants (Keq) were related to the temperature profile in the deposition zone and used in the proposed simulation. The validation of the model was carried out by measuring the temperature experimentally, where the temperature range on the substrate is 450 to 500 °C for different deposition parameters. In the simulation, the laminar flow of species contributing to the film growth was confirmed, and the simulated concentration profiles of H° and SiO near the filaments and the sources were as expected. H° and SiO are essential species for the subsequent growth of the SiOx films. These SiOx films have interesting properties and embedded nanostructures, which make them excellent dielectric, optoelectronic, and electroacoustic materials for the fabrication of devices compatible with silicon-based technology.

Modelling and Analysis of Low and Medium-Temperature Pyrolysis of Plastics in a Fluidized Bed Reactor for Energy Recovery

With the growing demand for plastic production and the importance of plastic recycling, new approaches to plastic waste management are required. Most of the plastic waste is not biodegradable and requires remodeling treatment methods. Chemical recycling has great potential as a method of waste treatment. Plastic pyrolysis allows for the cracking of plastic polymers into monomers with heat in the absence of oxygen, allowing energy recovery from the waste. Fluidized bed reactors are commonly used in plastic pyrolysis; they have excellent heat and mass transfer. This study investigates the influence of low and medium process temperatures of pyrolysis on fluidized bed reactor parameters such as static pressure, fluidizing gas velocity, solid movement, and bubble formation. This set of parameters was analyzed using experimental methods and statistical analysis methods such as experimental correlations of changes in fluidized bed reactor velocities (minimal, terminal) due to temperature increases for different particle sizes; CFD software simulation of temperature impact was not found. In this study, computational fluid dynamics (CFD) analysis with Ansys Fluent was conducted for the fluidization regime with heat impact analysis in a fluidized bed reactor (FBR). FBR has excellent heat and mass transfer and can be used with a catalyst with low operating costs. A two-phase Eulerian–Eulerian model with transient analysis was conducted for a no-energy equation and at 100 °C, 500 °C, and 700 °C operating conditions. Fluidizing gas velocity increases the magnitude with an increase of the operating temperature. The point of fluidization could be determined at 1.1–1.2 s flow time at the maximum pressure drop point. With the increase of gas velocity (to 0.5 m/s from 0.25 m/s), fluidizing bed height expands but when the solid diameter is increased from 1.5 mm to 3 mm, the length of the fluidized region decreases. No pressure drop change was observed as the fluidized bed regime was maintained during all analyses. The fluidization regime depends on gas velocity and all the applied fluidization gas velocities were of a value in between the minimal fluidization velocity and the terminal velocity.

Dielectric Barrier Discharge Reactors for Plasma‐Assisted CO2 and CH4 Conversion: A Comprehensive Review of Reactor Design, Performance, and Future Prospects

Dielectric barrier discharge (DBD) plasma is a promising technology for catalysis due to its low‐temperature operation, cost‐effectiveness, and silent operation. This review comprehensively analyzes the design and operational parameters of DBD plasma reactors for three key catalytic applications: CH4 conversion, CO2 splitting, and dry reforming of methane (DRM). While catalyst selection is crucial for achieving desired product selectivity, reactor design and reaction parameters such as discharge power, electrode gap, reactor length, frequency, dielectric material thickness, and feed gas flow rate, significantly influence discharge characteristics and reaction mechanisms. This review also explores the influence of less prominent factors, such as electrode shape and applied voltage waveforms. Additionally, this review addresses the challenges of DBD plasma catalysis, including heat loss, temperature effects on discharge characteristics, and strategies for enhancing overall efficiency.

Non-thermal plasma synergistic Ni/Al2O3 for ammonia synthesis: Configuration and optimization of a double dielectric barrier discharge reactor

The design of efficient reaction units and the use of efficient catalysts for green and non-polluting ammonia synthesis is an important and challenging issue. In this paper, we design a high-efficiency reaction device, a coaxial double dielectric barrier discharge plasma reactor, which produces a more uniform plasma discharge during operation, changes the discharge characteristics, promotes the physicochemical reactions of ammonia synthesis, improves the efficiency of ammonia production, and reduces the energy consumption. The use of transition metal Ni and its metal oxide NiO loaded on the carrier as catalysts. The catalyst was comprehensively characterized by X-ray photoelectron spectroscopy, X-ray diffraction, and scanning electron microscope. The reaction mechanism of plasma-catalyzed ammonia synthesis was studied in detail by combining discharge characteristics, optical emission spectroscopy, and catalyst characterization. The reaction conditions and discharge parameters of the dielectric barrier discharge plasma reactor were optimized, which greatly improved the energy efficiency and synthesis rate, which could reach 1002 μmol g−1 h−1 under the optimal conditions. Based on the experimental results, we analyzed how different conditions and parameters affect the reaction of ammonia synthesis.

The mass transfer during the dissolution of boric acid in water intensified by mechanical stirring

The kinetics granules of boric acid (GBA) dissolution were investigated based on the solution temperature and stirring frequency. Experimental mass transfer coefficients were determined and compared with theoretical values. The results indicate that increasing the stirring frequency and the solvent temperature increases the mass transfer coefficient. A computational relationship was derived, enabling the prediction of GBA dissolution based on solution temperature and stirring frequency. These findings highlight the significant impact of reactor parameters and mixing conditions on the mass transfer process in solid-liquid systems. The study’s results facilitate the simulation and optimization of mass transfer processes in solid-liquid systems, contributing to the optimization of chemical industry technological processes and reducing the energy consumption of the dissolution process.

Novel methodology for targeting the optimal reactor and operating parameters based on the chemical system’s overall performance within catalyst lifecycle

Catalyst deactivation affects chemical system performance and reactor operation. A systematic method is proposed for targeting the optimal reactor, operating parameters, system performance, and catalyst service life, considering the catalyst deactivation. Relations between reactor performance, operating parameters, and running time are clarified based on the coupling analysis of the reactions, catalyst deactivation kinetics, and mass/energy balance. The influence of reactor fluctuation on energy cost and product output is explored by topological analysis, pinch analysis, and algebraic reasoning. A reactor-separator-heat exchanger network coupling frame is established to predict system performance and guide the reactor selection, catalyst regeneration, and system adjustments. The proposed method is intuitive and efficient and can be applied in the preparatory/operation stage. For the studied benzene hydrogenation process, the Plug Flow Reactor is suitable; the catalyst’s optimal service life is 2.08 y, achieving 4.4 % and 4.8 % decreases in annual cost and energy demand/carbon emission by real-time adjustments.

Online monitoring method for inter-turn short circuit fault of dry-type hollow core reactor

Abstract A method for online monitoring of turn-to-turn short circuit faults based on power factor changes is proposed to solve the problem of small overall current changes and delayed overcurrent protection after the occurrence of turn-to-turn short circuit faults in dry-type hollow reactors. A circuit model of inter-turn short-circuit fault reactor was established, and the changes in electrical parameters of the fault reactor were numerically analyzed at different positions. On this basis, the power factor was determined as the monitored variable, and a test platform was built for experimental verification. The research results indicate that after a turn-to-turn short circuit fault, the total current changes very little, the power factor increases significantly, and the changes in various electrical parameters are related to the location of the short circuit. The experimental results are consistent with the theoretical analysis results, verifying the correctness and effectiveness of the monitoring method.

Ammonia recovery from real biogas slurry in the up-scaled Donnan Dialysis-Osmotic Distillation membrane-based system: Performance and potentials

Recovering ammonia from wastewater is crucial for building a circular economy and achieving carbon neutrality. Some innovative ammonia recovery technologies have shown great potential yet lacking theoretical guidance for up-scaling from laboratory to practical applications. Herein, upon our previously-proposed Donnan dialysis-osmotic distillation (DD-OD) hybrid process for selective ammonia recovery at nearly zero energy input, two challenges as process modelling/prediction and product application were solved in this study. Under the guide of the tailor-made mass transfer model, a reasonable design of the reactor and operating parameters was fixed, whose performance in recovering ammonia from real biogas slurry and the feasibility of the recovered product as irrigation water was then investigated. The up-scaled DD-OD reactor achieved efficient and stable ammonia removal and recovery (∼75 % and ∼ 65 %, respectively) and excellent impurity retention efficiency (∼95 %) in 360 h continuous run. Impurities deposited on the cation-exchange membrane did not affect ammonium transfer and were effectively removed by water washing, and no fouling was found for the hydrophobic membrane, highlighting its long-term capability for ammonia recovery. Moreover, the cost-effectiveness of the process was analyzed, which could be greatly improved given the future improved membrane materials. A proper dilution of the recovered product for irrigating cabbage and radish promoted plant growth, and recycled product containing a moderate ammonia concentration (136 mg/L) was highlighted, with a well-rounded, multi-element nutrient profile recommended. The above results provide theoretical guidance for the scaling-up of ammonia recovery module and a potential pathway for the application of recycled products in agricultural irrigation.

Optimizing neural network models for predicting nuclear reactor channel temperature: A study on hyperparameter tuning and performance analysis

This study emphasizes how important accurate prediction of channel temperatures in nuclear reactors is for safety and operational efficiency. While traditional methods require long and complex processes such as kernel modeling and mathematical simulations, artificial neural networks (ANN) provide more efficient predictions by accelerating this process. The superior ability of ANNs to process large data sets is intended to demonstrate that this study will provide a valuable alternative compared to conventional methods and increase the accuracy of reactor temperature predictions. In this study, the training performances of Artificial Neural Network (ANN) developed to determine the nuclear reactor channel temperature with different hyperparameter combinations were analysed. It was conducted several experimental studies to assess the influence of hyperparameters on our model for nuclear reactor parameter data prediction. The training and validation results indicates that learning rate, hidden layer sizes and number have critical effects for the more precisive prediction. It was observed that models with a learning rate of 0.05 and 0.5 achieved successful learning with less fluctuation in training and validation errors. When looking at hidden layer sizes, networks with 32 and 64 neurons performed better than networks with 16 neurons. For the test phase our model can successfully predict data with slight error margin. As a result, we demonstrated that neural networks are a powerful tool in nuclear reactor channel temperature prediction through our proposed model.

Enhanced syngas production through dry reforming of methane with Ni/CeZrO2 catalyst: Kinetic parameter investigation and CO2-rich feed simulation

Natuna's natural gas reserve, which contains 70 %–v CO2 and 30 %–v CH4, opens a prospective method for producing syngas through the dry reforming of methane (DRM). This study used the equation and determination of kinetic parameters in a fixed-bed reactor to develop the operating conditions for the DRM process. The catalyst used was 10 %Ni/CeZrO2 and followed the Langmuir-Hinshelwood mechanism, with CH4 dissociation (activation of C–H bonds) on the Ni catalyst as the rate-determining step. According to the results, the simulation and experimental data have error values of ≤ 5 % and RMSE < 0.046. This indicates that the equation and kinetic parameters used in the simulation are valid for reactor modeling. Steady-state modeling was then conducted using a 1D quasihomogeneous model. The feed composition of CO2:CH4 = 70:30 (Natuna gas field composition) has optimized results with temperature 700 °C, CH4 conversion at 92 %, CO2 conversion at 28 %, and H2/CO ratio 1.42, and carbon formation at 7.1 mgC/gcat. This study also found that a higher CO2:CH4 feed ratio could reduce carbon formation during DRM.

Influence of design and operational parameters of a Taylor flow reactor on the bioconversion of methane to ectoines

Ectoine is one of the most attractive bioproducts due to its high market price and applications. Methanotrophic bacteria can synthesize ectoine from biogas. In this work, key design and operating parameters were optimised to maximise the bioconversion of methane to ectoine in a novel Taylor Flow bioreactor. This bioreactor configuration is characterized by higher gas-liquid mass transfer coefficients compared to conventional bubble column bioreactors. Thus, the influence of the internal gas recirculation flow rate (1.0 L·min−1, 2.5 L·min−1, 4.0 L·min−1, 5.5 L·min−1) at 60 and 120 min of gas residence time (GRT), the liquid recirculation flow rate (0 L·h−1, 141 L·h−1, 165 L·h−1, 395 L·h−1, 434 L·h−1) and the capillary length (1.50 and 0.75 m) was evaluated using a mixed methanotrophic consortium. Process operation at 120 min of GRT and 5.5 L·min−1 of gas recirculation flow rate enhanced methane bioconversion, resulting in a maximum efficiency of 83.8 ± 2.7 %. The decrease in capillary length from 1.5 to 0.75 m did not enhance methane bioconversion. Intracellular ectoine and hydroxyectoine reached maximum contents of 105.1 ± 8.6 mgEC·gTSS−1 and 33.4 ± 11.7 mgHE·gTSS−1, respectively. Nitratireductor was the dominant genus, while Methylomicrobium and Methylophaga were the main methanotrophic bacteria detected in the consortium. This study confirmed the feasibility of bioconverting novel renewable feedstocks such biogas into high-added value bio-products, boosting the circular and carbon neutral economy in bio-based industries.

ERCAD: A Parametric Reactor Design Tool That Enables Rapid Prototyping and Optimization of Electrochemical Reactors through 3D Printing.

The reactors are an essential component of electrosynthetic reactions. As the electron transfer processes are heterogeneous, the reactors have a significant impact on reaction outcomes. This has resulted in reaction reproducibility being problematic, which commercial reactors alleviate somewhat but are expensive and cannot be optimized or iterated upon. Using 3D printing, rapid prototyping of bespoke reactors should facilitate investigation of the sensitivity of key reactor parameters, enable reactor optimization, and improved reproducibility through sharing of the print files. However, the bottleneck to this approach is the Computer Aided Design (CAD) of the reactors, which typically requires specialist knowledge and training to do. This has resulted in 3D printing not being typically used in the field of electrosynthesis. Herein, we showcase the development and application of a user-friendly, open-source software tool that can be used to produce Electrochemical Reactor CAD (ERCAD) designs simply and easily by nonexperts. We demonstrate its use to design and print reactors for the analysis, optimization, screening, and scaleup of electrosynthetic reactions. Using this parametric design tool, chemists with no design experience or skills can now easily create, print, test, and share their reactors.

Process deviation detection method for dry‐type air‐core reactor based on power factor frequency characteristics

AbstractTo address the problem that the process deviation of dry‐type air‐core reactors cannot be effectively detected, electrical parameters of reactor are numerically analysed at different frequencies. A new method of process deviation detection by the power factor frequency characteristic is proposed. Considering on‐site power frequency interference, a harmonic analysis method is proposed, which is based on the integer multiple of the power frequency cycle, to calculate the power factor. The results show that the resistance loss remains relatively constant at power frequency and gradually increases at higher frequencies with the number of deviation turns increases. The eddy current loss remains basically unchanged at different turn deviations and frequencies. The change laws of resistance loss and the resistance loss power factor are the same. In a double logarithmic coordinate system, resistance loss power factor changes from linear to non‐linear. The non‐linearity degree can be used to detect the process deviation. The test results are consistent with the theory, and the correctness of the detection method is verified.

Heat transfer optimization for MH reactor using combined taguchi design and data-driven optimization method

Adding the heat transfer enhancement components into the MH reactor can improve the hydrogen absorption/desorption rate, but the vital indicators as the gravimetric and volumetric hydrogen storage density decrease at the same time, which is hardly considered in the published researches. In this study, a comprehensive hydrogen storage performance (CHSP) indicator for the MH reactor has been proposed considering the above contradiction, which can be applied to evaluate the comprehensive performance of the MH reactor and compare the reactor performances with different heat transfer configurations. Then, with the constraint of the CHSP, the heat transfer structure of the classical finned-tube MH reactor is optimized using a novel sieving optimization strategy which combines the Taguchi design and the data-driven optimization (ANN model + GA) to increase the optimization efficiency and the reliability of optimization solutions. The optimized results indicate that the optimal structural parameters of the finned-tube MH reactor are the diameter of heat exchange tube d of 5.13 mm, the fin thickness h of 0.28 mm, the fin radius r of 21.73 mm and the fin number N of 11, and the optimal CHSP is 0.547 mg/s.

Effect of linear antenna chemical vapor deposition process parameters on the growth of nanocrystalline diamond-on-GaN films

The present work will systematically study the effect of different linear antenna microwave plasma enhanced chemical vapor deposition (LACVD) processing parameters on the optimal deposition of the diamond films. The low pressure and low temperatures of LACVD growth conditions is expected to deposit diamond films on otherwise reactive gallium nitride (GaN) surfaces, without any intermediate nitride buffer layer. First, the distances between the quartz tube and the samples put on the stage are varied (3–15 cm), which has a direct impact on the substrate temperature (415°–300 °C). Thereafter, the microwave input power was also altered (1.5–2.8 kW) to attain low substrate temperatures. It was found that 300 °C is the temperature limit, which can be attained by heating only with microwave plasma when the substrates are kept farthest (15 cm) away from the liner antenna quartz tube. An additional heater was used under the stage for rapidly achieving such minimum substrate temperature of 300 °C. Substrate heater was used for efficient growth of the diamond phase while using pulse mode frequency of microwave power input for optimization of the diamond films. The microstructure (plate-like and cauliflower-like) of the deposited nanocrystalline diamond (NCD) films and the cross-sectional images for thickness measurements was observed under the scanning electron microscope and the elemental analysis of the film surfaces was done by electron diffraction spectroscopy. Moreover, the diamond film quality and crystallinity were evaluated by Raman spectroscopy with 488 nm laser light. Diamond-on-GaN film results were compared with conventional Si substrate. Different LACVD reactor parameters like, antenna to stage distances, microwave input power in continuous wave mode, and growth temperatures have significant impacts on the grown films, both in terms of their quality and microstructure. It was found that the optimum deposition of nanocrystalline diamond film on GaN substrates without its surface etching was possible, under pulse mode (20 kHz, 45 % duty cycle) with 2 kW average input microwave power.

Simulation of hexavalent chromium removal by electrocoagulation using iron anode in flow-through reactor

An electrocoagulation (EC) model is developed for hexavalent chromium reduction and precipitation, using iron electrodes. Parallel removal mechanisms such as adsorption of chromium on ferrihydrite and direct reduction at the cathode is assumed negligible due to low concentration of Cr(VI). The reaction model presented for batch system represents species complexation, precipitation/dissolution, acid/base, and oxidation-reduction reactions. Batch reactor simulation is verified using experimental data obtained by Sarahney et al. (2012), where the effect of initial chromium concentration, pH, volumetric current density, and ionic strength is considered (Sarahney et al., 2012). The model couples multicomponent ionic transport in MATLAB with chemical reaction model in PHREEQC, as a widely used computational programming tool and a geochemical reaction simulator with comprehensive geochemistry databases. The suggested current density is 0.05−0.3mA/cm2 and the surface to volume ratio in batch reactor is considered 0.017 1/cm. Design parameters are presented for operation of a flow-through hexavalent chromium removal using electrocoagulation by iron electrode to treat Cr(VI) in range of 10–50 mg/L. The operational parameters for a flow-through EC reactor for Cr(VI) removal is suggested to follow 0.05mA/cm2≤3nFeQcCrVIinlet≤0.3mA/cm2.

Ta–W metal alloy membrane reactor for HI decomposition in I–S thermochemical cycle for hydrogen production

HIx processing section of Iodine-Sulfur (IS) thermochemical cycle suffers from the drawbacks of highly corrosive environment and a low thermodynamic conversion of HI decomposition (∼22% at 450 °C). This study investigates, for the first time, the potential of tantalum-tungsten (Ta–W) metal alloy membrane reactor for the decomposition of HI. A thin film of Ta–W alloy was deposited on clay-alumina support by DC magnetron sputtering under optimized set of parameters. The corrosion resistance of the Ta–W membrane was evaluated through electrochemical corrosion studies and immersion coupon tests in azeotropic HI (57 wt % in water) environment. The results confirmed that Ta–W had a higher corrosion resistance than Ta. HI decomposition was carried out in Ta–W membrane reactor and suitable operating parameters were finalized. An enhanced conversion of ∼98% was obtained at 450 °C and 105 Pa, while no permeation of HI, water and iodine was observed across the membrane.