Design of a catalytic methane-to-proton exchange membrane fuel cell (PEMFC) grade hydrogen conversion system consisting of indirect partial oxidation (IPOX), water-gas shift (WGS) and preferential carbon monoxide oxidation (PROX) reactors is investigated using modeling and simulation techniques. Steady-state simulation, design and sizing of reactors, which are considered to be packed-bed tubular type, are carried out for twelve different feed composition and PEMFC power output configurations, namely (CH4/O-2, H2O/CH4) = (2.24, 1.17), (1.89, 1.56) and (10, 50, 100, 500, 1000, 1500 W). For every configuration, material balance calculations are executed to obtain the flow rates of each species at each stream. These results are then used as boundary conditions to estimate the catalyst weights in each reactor via simulations conducted using a one-dimensional pseudo-homogeneous reactor model. Finally, reactor and catalyst particle dimensions are estimated by considering pressure drop and a set of criteria to quantify interfacial heat and intraparticle mass transfer resistances and fluid flow characteristics in packed beds. The total catalyst quantity is found to increase almost linearly with the PEMFC power output at both feed compositions. Total system volume, excluding piping, pumping, heat exchange and other peripheral units, is estimated to be 6.3, 40.3, 83.4, 488, 985 and 1527 cm(3) for 10, 50, 100, 500, 1000 and 1500 W operations, respectively. WGS unit requires the highest space corresponding to ca. 50% of the total reactor volume, followed by IPOX (ca. 39%) and PROX (ca. 11%) reactors. Power densities, based on the weight and volume of the reactors are estimated as 1.1 kW/kg and 1.2 kW/l, respectively. (c) 2008 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.