Solid-state NaBH4/Ru-based catalyst composites have been fabricated for hydrogen generation through a high-energy ball-milling process, providing uniform dispersion of resin-supported Ru3+ catalysts among pulverized NaBH4 (SBH) particles, so as to increase the contacts of SBH with active catalytic sites. Consequently, the gravimetric hydrogen storage capacity as high as 7.3 wt% could be achieved by utilizing water as a limiting reagent to overcome the issue of deactivated catalysts whose active sites are often blocked by precipitates caused by limited NaBO2 Solubility occurring in conventional aqueous SBH systems for hydrogen productions. Products of hydrolyzed SBH that greatly influence the gravimetric H-2 storage capacity are found to be most likely NaBO2 center dot 2H(2)O and NaBO2 center dot 4H(2)O from SBH/H2O reacting systems with initial weight ratios, SBH/H2O = 1/2 and 1/10, respectively, according to the TGA and XRD analyses. (C) 2010 Elsevier B.V. All rights reserved.