A I kW, hydrogen generation system using hydrolysis of sodium borohydride (NaBH4) has been designed and built. The effects of flow rate, fuel concentration, inlet temperature and operating pressure on chemical conversion have been systematically investigated. A 10-point thermocouple profile probe was used to measure the temperature distribution inside the catalyst bed. Chemical conversion was also qualitatively evaluated via the temperature profile. For the present adiabatic reactor, a large temperature gradient at the outlet implies low conversion, while a small temperature gradient at the outlet implies high conversion. In order to obtain accurate measurements of hydrogen flow rate, water vapor carried in the product stream was removed by a custom hydrogen conditioning station. Using 15% concentration NaBH4 aqueous solution, this system generated hydrogen up to 20 SLPM with a reasonably high chemical conversion (95%). Discharge products from using NaBH4 concentrations above 15% crystallized upon cooling to room temperature. Such products would be difficult to remove from the discharge tank in a practical setting. Considering the practical difficulties in heating the discharge product to prevent crystallization, the highest usable concentrations would likely fall in the range of 10-15%. The resulting maximum material gravimetric density is 3.1 wt% of hydrogen and falls short of the DOE on-board hydrogen storage system target of 6 wt% for year 2010. (c) 2007 Elsevier B.V. All rights reserved.