Fuel cell vehicles have reached the commercialization stage and hybrid vehicles are already on the road. While hydrogen storage and infrastructure remain critical issues in stand alone commercialization of the technology, researchers are developing onboard fuel processors, which can convert a variety of fuels into hydrogen to power these fuel cell vehicles. The feasibility study of a 100 kW on board fuel processor based on gasoline fuel is carried out using process simulation. The steady state model has been developed with the help of Aspen HYSYS to analyze the fuel processor and total system performance. The components of the fuel processor are the fuel reforming unit, CO clean-up unit and auxiliary units. Optimization studies were carried out by analyzing the influence of various operating parameters such as oxygen to carbon ratio, steam to carbon ratio, temperature and pressure on the process equipments. From the steady state model optimization using Aspen HYSYS, an optimized reaction composition in terms of hydrogen production and carbon monoxide concentration corresponds to: oxygen to carbon ratio of 0.5 and steam to carbon ratio of 0.5. The fuel processor efficiency of 95.98% is obtained under these optimized conditions. The heat integration of the system using the composite curve, grand composite curve and utility composite curve were studied for the system. The most appropriate heat exchanger network from the generated ones was chosen and that was incorporated into the optimized flow sheet of the 100 kW fuel processor. A completely heat integrated 100 kW fuel processor flow sheet using gasoline as fuel was thus successfully simulated and optimized. (C) 2013 Elsevier Ltd. All rights reserved.