This study explains completely feasible route to synthesize NaBH4 by means of mechano-chemical reaction, in which NaCl, B2O3 and MgH2 were utilized. Optimum reaction conditions were investigated by different values of reactant ratio and duration to reach 95% NaBH4 purity. In addition, commercial NaBFLI was hydrolyzed with Col(2) supported on activated carbon (AC). Intermediate steps of the studies were traced by means of FT-IR, XRD, SEM and EDX analyses. Activation energy of the catalyst was searched at distinct reaction temperatures and found as 36 kJ/mol. Optimum working time for ball-milling reactor and reactant ratio (MgH2/NaCl) were obtained as 1000 min and 1.0, respectively. (C) 2013 Elsevier Ltd. All rights reserved.