A Cu/ZnO/Al2O3 catalyst suitable for low-temperature methanol reforming is proposed. The catalyst achieved by optimization of the temperature and pH of preparation and the addition of boehmite has superior catalytic activity to commercial catalysts. The catalytic activity is found to depend on the Cu surface area, which is related to the amount of Cu dispersed within ZnO. Dispersion of Cu is promoted by precipitation at low temperature, which results in the formation of small crystallites of the precursor. Enlarged BET surface area by the addition of boehmite as the third component derives high catalytic activity. Under optimized pH, it is predicted that the excess of Cu species existing as amorphous-like malachite in the precursor, in addition to aurichalcite, facilitates the dispersion of Cu. The proposed catalyst system can achieve methanol reforming at temperatures 20-25 degrees C lower than conventional catalysts, representing an improved source of H-2 for small proton exchange membrane fuel cell systems. (c) 2005 Elsevier B.V. All rights reserved.