In the present work, a microchannel reactor for autothermal reforming of methanol using a synthesized catalyst porous alumina support-CuO/ZnO mixed with ZrO₂ sol washcoat has been developed and its fine structure and inner surface characterized. Experimentally, CuO/ZnO and alumina support with ZrO₂ sol washcoat catalyst (catalyst slurries) nanoparticles is the catalytically active component of the microreactor. Catalyst slurries have been dried at 298 K for 5 h and then calcined at 623 K for 2 h to increase the surface area and specific pore structures of the washcoat catalyst. The surface area of BET N₂ adsorption isotherms for the as-synthesized catalyst and catalyst/ZrO₂ sol washcoat samples are 62 and 108 ± 2 m²g⁻¹, respectively. The intensities of Cu content from XRD and XPS data indicate that Al₂O₃ with Cu species to form CuAl₂O₄. The EXAFS data reveals that the Cu species in washcoat samples have Cu-O bonding with a bond distance of 1.88 ± 0.02 Å and the coordination number is 3.46 ± 0.05, respectively. Moreover, a hydrogen production rate of 2.16 L h⁻¹ is obtained and the corresponding methanol conversion is 98% at 543 K using the CuO/ZnO with ZrO₂ sol washcoat catalyst.