A micro-channel reactor for methanol steam reforming is a candidate to supply hydrogen on-site to fuel cells. Micro-channel beds wash-coated with poor quality slurry formulations lead to poorer performance than packed beds using pellet catalysts. This study explored the morphology, X-ray Diffraction (XRD) spectrum, BET surface area and activity of wash-coating catalyst layers from a series of catalyst slurries. All catalyst slurries were prepared from the commercial MDC-3 catalyst. Hydrogen production using wash-coating catalyst layers was performed under packed bed conditions. The results reveal that the solubility level of the MDC-3 catalyst during the slurry preparation process affected the activity of methanol steam reforming. It is difficult to reconstruct the original fine structure, as the MDC-3 catalyst had a higher solubility status after slurry preparation. The volume of the micro-channel catalyst bed was approximately 0.3 cm(3). It can supply hydrogen to fuel cells that can produce approximately 8W with 80% H-2 utilization and 60% fuel cell efficiency. Copyright (C) 2011, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.