NOVELTY - A fuel processor (15) comprises bottom plate having regenerator with first inlet to receive air flow; burner flow chamber within regenerator, having second inlet to receive air flow from regenerator; and reformer flow chamber between regenerator and burner flow chamber, having third inlet to receive air flow from burner chamber. The burner flow chamber and reformer flow chamber are formed of monolithic structure (100) having elongated, rounded baffle in a center of the monolithic structure.    USE - Fuel processor for fuel cell system, such as reformed methanol fuel cell, solid oxide fuel cell, phosphoric acid fuel cell, direct methanol fuel cell, and direct ethanol fuel cell.    ADVANTAGE - The fuel processor is capable of carrying out reactions under controlled temperatures to improve its performance by preventing hot and cold spots, efficiently converts hydrocarbon fuel source to hydrogen, and preserves integrity of catalyst in the catalytic chamber.    DETAILED DESCRIPTION - The fuel processor (15) comprises bottom plate having regenerator with first inlet to receive air flow; burner flow chamber within regenerator, having second inlet to receive air flow from regenerator; and reformer flow chamber between regenerator and burner flow chamber, having third inlet to receive air flow from burner chamber. The burner flow chamber and reformer flow chamber are formed of monolithic structure (100) having elongated, rounded baffle in a center of the monolithic structure. A top plate having top and bottom surfaces is coupled to the bottom plate to enclose the fuel processor. An INDEPENDENT CLAIM is included for a method for manufacturing the fuel processor. The burner flow chamber or reformer flow chamber further comprises catalyst chambers. The catalyst is a thermally conductive substrate having an alumina layer with an active catalyst deposited on it. The substrate is an aluminum porous metal or an aluminum metallic sponge.    DESCRIPTION OF DRAWING(S) - The drawing is an exploded perspective view of the fuel processor.    Fuel processor (15)    Monolithic structure (100)    End plates (182, 184)    Interconnect (200)    Outlet port (209)