Recycling of concentrated HCl within the Cu-Cl cycle for hydrogen production is necessary to achieve lower operating costs and higher efficiency. HCl and water molecules have an attraction that leads to a maximum boiling azeotrope. Thus, HCl cannot be separated from water by using a conventional distillation column. In this paper, a novel thermodynamic model and simulations in Aspen Plus are presented for a pressure swing distillation high-pressure process to separate the HCl-water azeotropic binary mixture into a concentrated HCl stream. Furthermore, a heat transfer analysis is presented to predict the packing column height. All of the stream properties and compositions in the binary azeotropic mixture, thermodynamic analysis and steady-state simulation of a high pressure distillation column are examined with Aspen Plus. The present results indicate that the high-pressure distillation system enhances the mole fraction of HCl (aq) from 0.11 up to 0.21 and the increase of reflux ratio and feed temperature assist it to be higher. The increment of 76% and 42% for the condensation and re-boiler heat duties with the growth of reflux ratio indicate the significant impact of this parameter on the high pressure distillation column. Furthermore, at the specific system operating condition, the results from the heat transfer model suggest that the distillation column with a height of 2 m would be suitable for practical operation. (C) 2018 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.