In this study, the effect of different process variables on the washcoating of Ni/MgAl2O4 on FeCralloy foils and monoliths has been investigated and the washcoated monolith tested for the steam reforming of methane. Washcoating parameters, such as calcination temperature after washcoating, addition of binders, particle size of the slurry after ball milling, and rheological properties of the slurry, not only affected the loading and adherence of the washcoat, but also significantly affected the physicochemical properties of the catalyst. Slurry milled for 48 h (average particle size similar to 2 mu m) of pH 2-4 was found to be most stable and resulted in homogeneous washcoating. Increasing the calcination temperature after washcoating from 600 to 800 degrees C decreased the weight loss observed during adhesion test. However, the weight loss of the washcoat was still significant. Furthermore, typical procedures for sol coating of the metal monolith, before slurry washcoating, did not improve adhesion of Ni/MgAl2O4 washcoating on the FeCralloy metal. However, addition of binders (2 wt % poly(vinyl alcohol) and 4 wt % colloidal alumina) to the milled Ni/MgAl2O4 slurry significantly improved the adhesion of the washcoated slurry. Catalyst characterization of washcoat slurry catalyst revealed that milling of the slurry increased the catalytic surface area and active metal dispersion. Washcoated monolith subjected to activity test for steam reforming of methane reaction was found to be more active in comparison to a packed bed reactor.