A novel nano CuZnAl-spinel catalyst has been successfully synthesized and tested for autothermal steam reforming of methanol to produce onboard hydrogen for fuel cell applications. The catalyst performance has been studied using three crucial operating parameters, namely, the methanol space velocity, molar ratios of water/methanol and oxygen/methanol. The effects of these parameters have been investigated in terms of methanol conversion and hydrogen production rate. The optimal hydrogen production rate of about 575 mmol kg(-1)s(-1) has been achieved at 300 degreesC in this study. (C) 2004 Elsevier B.V. All rights reserved.