Commercial WC-10Co-4Cr powder was sprayed by a novel HVOF process with ethanol fuel. The ethanol fuel benefits from environmentally friendly feature and less consumption of oxygen gases compared to some conventional fuels (i.e. kerosene). Taguchi experiment program was employed for optimizing series spraying parameters (oxygen flow rate, ethanol flow rate, etc.), as a result of understanding the influence of these parameters on the properties of WC-10Co-4Cr coatings. The phase compositions, microstructures and porosities were characterized by XRD and SEM analyses. Besides, the microhardness and wear resistance were tested for comparation. The results indicate that the phase composition of the resultant coatings is insensitive to spraying parameters. By contrast, these factors possess obvious effects on the microhardness, porosities and deposition efficiencies of these coatings. The comparative mechanical performances of WC-10Co-4Cr coatings were achieved by the novel HVOF torch, suggesting high-interest of this process due to the aforementioned advantages of ethanol fuel.