This work explores the use of falling film technology to generate hydrogen from BH4- hydrolysis reaction. A technique to create catalytic sites on Ni foam struts by surface alloying is also developed. Mg-Ni and Al-Ni intermetallic compounds (catalyst precursor) are formed when Ni foams loaded with Mg and Al powders are heated to 600 degrees C under N-2 atmosphere, respectively. The catalytic sites of Mg2Ni and Raney Ni are formed on Ni foam struts after treating surface-alloyed Ni foams with an alkaline BH4- solution. Raney Ni on Ni foam struts (Raney Ni foam) has higher catalytic activity than Mg2Ni on Ni foam struts. The Raney Ni foam reaction plate in falling film reactor demonstrates high catalytic activity and quick response to fuel feed in H-2 generation. (c) 2013 Elsevier B.V. All rights reserved.