A structured Co-B catalyst has been developed to produce hydrogen from an alkaline NaBH4 solution. The catalyst was prepared by chemical reduction of Co precursors coated on a Ni foam support. The effects of catalyst preparation conditions on activity of the catalyst were investigated. The active catalyst was amorphous in structure and contains boron with a Co/B molar ratio of 1.5-2.8. With increasing the heat treatment temperature, the catalyst showed a maximum activity to hydrogen generation at approximately 250 degrees C. Adhesion of the catalyst to the support was also enhanced by heat treatment at 300-400 degrees C. The catalysts were successfully applied in both a batch reactor and a flow reactor for continuous generation of hydrogen. (c) 2006 Elsevier B.V. All rights reserved.