The paper describes the design and performance of a breadboard prototype for a 5 kW fuel-processor for powering a solid oxide fuel cell (SOFC) stack. The system was based on a small, modular catalytic Microlith auto-thermal (ATR) reactor with the versatility of operating on diesel, Jet-A or JP-8 fuels. The reforming reactor utilized Microlith substrates and catalyst technology (patented and trademarked). These reactors have demonstrated the capability of efficiently reforming liquid and gaseous hydrocarbon fuels at exceptionally high power densities. The performance characteristics of the auto-thermal reactor (ATR) have been presented along with durability data. The fuel processor integrates fuel preparation, steam generation, sulfur removal, pumps, blowers and controls. The system design was developed via ASPEN (R) Engineering Suite process simulation software and was analyzed with reference to system balance requirements. Since the fuel processor has not been integrated with a fuel cell, aspects of thermal integration with the stack have not been specifically addressed. (c) 2006 Elsevier B.V. All rights reserved.