For direct internal reforming (DIR) in molten carbonate fuel cells (MCFCs), steam reforming of methane has been carried out over Ni/gamma-Al2O3 catalysts prepared by a homogeneous precipitation method. During the synthesis of Ni/gamma-Al2O3 catalysts, various synthesis parameters have been systematically manipulated to develop a highly active and KOH-resistant catalyst for DIR in MCFCs. Compared with a commercial catalyst, 52% Ni/gamma-Al2O3 prepared with a precursor concentration of 0.18 M and a urea concentration of 6 M exhibited very high activity with strong resistance against KOH due to the selective adsorption of KOH on the gamma-Al2O3 support. (C) 2010 Elsevier B.V. All rights reserved.