Abstract The paper shows the preliminary design of the superheated steam generator to be used in a novel hydrogen production and energy conversion system based on the combustion of aluminum particles with water. The system is aimed at producing hydrogen and pressurized superheated steam, using the heat released by the Al–H2O reaction. The interest on this type of technology arises because of the possibility of obtaining hydrogen with very low pollutant and greenhouse gas emissions, compared to the traditional hydrogen production systems, such as the steam reforming from methane. The analysis of the combustion chamber and the heat recovery system is carried out by means of a lumped and distributed parameter numerical approach. The multi phase and gas mixture theoretical principles are used both to characterize the mass flow rate and the heat release in the combustion chamber and within the heat exchangers in order to relate the steam generator performance to the system operating parameters. Finally, the influence of the steam generator performance on the whole energy conversion system behavior is addressed, with particular care to the evaluation of the total power and efficiency variation with the combustion parameters.