Using a liquid fuel to run a fuel cell system becomes more attractive, when a simple and robust fuel processor can be developed. Conversion of a liquid methanol/water-mixture needs a series of process steps to supply hydrogen to a fuel cell. Based on an approach using new material these processes are combined in an integrated fuel processor (IFP). We apply technologies from powder metallurgy like pressing and sintering, to fix catalyst powder and to shape complex functional structures. As a consequence of the new material approach, the IFP can be built as a monolith without any sealing. The good isotropic heat conductivity helps to thermally couple the processes. Experimental results on a level of about 201 of hydrogen per minute demonstrate the feasibility of the concept. Supported by modelling, alternative schemes of reactor design indicate potential for optimisation. (C) 2003 Elsevier Science B.V. All rights reserved.