A plate-type integrated fuel processor consisting of three different micro-structured modules was developed for hydrogen production in a 150W PEMFC system. This system includes a reformer with combustor, two heat exchangers, and an evaporator with a combustor. Methanol steam reforming was chosen as a means to produce hydrogen for the PEMFC system. This system could be operated without any external heat supply. Hydrogen was used as the initial combustion fuel during startup, while methanol was used later. Cu/Zn/Al2O3 and Pt/Al2O3 catalysts were chosen for the steam reforming of methanol and the combustion, respectively, and coated on microchannel-patterned stainless steel sheets. The integrated system was operated consistently with 80% of methanol conversion at 300 degrees C for 20h without deactivation of the catalysts. The production rate on dry basis and the composition of hydrogen was 2.4 NL min(-1) and ca 70%, respectively. Overall the thermal efficiency of this fuel processor based on the LHV was 56.7%. (c) 2007 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.