Aluminium appears to be a promising material for on-board hydrogen generation in fuel cell applications given the comparatively large amount of hydrogen produced per gram of aluminium in a safe system. A microfuel processor with aluminium and water as reactants is developed in a flow reactor for application in portable power sources. Two types of reactor are used. One reactor permits the direct feeding of liquid water in channels containing aluminium pellets, whereas the other utilizes the heat produced from the reaction to vapourize liquid water before entry into the reactor. Two additives, namely, calcium oxide (CaO) and sodium hydroxide (NaOH), are used to enhance the reaction rate. A maximum conversion of 78.6% with respect to aluminium is achieved when the water entering in the reactor is vapourized partially. In the case of liquid water entering the reactor, the conversion is 74.4%. (C) 2007 Elsevier B.V. All rights reserved.