Microstructural characteristics of various real Cu/ZnO/Al2O3 catalysts for methanol steam reforming (MSR) were investigated by in situ X-ray diffraction (XRD), in situ X-ray absorption spectroscopy (XAS), temperature programmed reduction (TPR) and electron microscopy (TEM). Structure-activity correlations of binary Cu/ZnO model catalysts were compared to microstructural properties of the ternary catalysts obtained from in situ experiments under MSR conditions. Similar to the binary system, in addition to a high specific copper surface area the catalytic activity of Cu/ZnO/Al2O3 catalysts is determined by defects in the bulk structure. The presence of lattice strain in the copper particles as the result of an advanced Cu-ZnO interface was detected only for the most active Cu/ZnO/Al2O3 catalyst in this study. Complementarily, a highly defect rich nature of both Cu and ZnO has been found in the short-range order structure (XAS). Conventional TPR and TEM investigations confirm a homogeneous microstructure of Cu and ZnO particles with a narrow particle size distribution. Conversely, a heterogeneous microstructure with large copper particles and a pronounced bimodal particle size distribution was identified for the less active catalysts. Apparently, lattice strain in the copper nanoparticles is an indicator for a homogeneous microstructure of superior Cu/ZnO/Al2O3 catalyst for methanol chemistry. (C) 2008 Elsevier B.V. All rights reserved.