A safe and simple hydrogen generator, which produced hydrogen by chemical reaction of aluminum and sodium hydroxide solution, was proposed for proton exchange membrane fuel cells. The effects of concentration, dropping rate and initial temperature of sodium hydroxide solution on hydrogen generation rate were investigated. The results showed that about 38 ml min(-1) of hydrogen generation rate was obtained with 25 wt.% concentration and 0.01 ml s(-1) dropping rate of sodium hydroxide solution. The cell fueled by hydrogen from the generator exhibited performance improvement at low current densities, which was mainly due to the humidified hydrogen reduced the protonic resistivity of the proton exchange membrane. The hydrogen generator could stably operate a single cell under 500 mA for nearly 5 h with about 77% hydrogen utilization ratio. (C) 2008 Elsevier B.V. All rights reserved.