Monolith based catalytic partial oxidation process for syngas production

Abstract

An improved process for the catalytic partial oxidation of hydrocarbons to produce hydrogen and carbon monoxide and less than ˜2% carbon dioxide is disclosed. The process further permits the reaction to be initiated at room temperature, and utilizes a metal catalyst deposited on a ceria-coated zirconia monolith support, which exhibits high conversions of hydrocarbons to synthesis gas (hydrogen and carbon monoxide).

1 . A reactor comprising a vessel, at least one ceramic foam disk impregnated with a catalytic material and at least one blank ceramic foam disk.  
     
     
         2 . The reactor as claimed in  claim 1  wherein said vessel is refractory lined.  
     
     
         3 . The reactor as claimed in  claim 1  which is in the shape of a pipe or tube and has a diameter of about 1 to about 100 inches.  
     
     
         4 . The reactor as claimed in  claim 1  wherein said catalytic material comprises zirconia coated with ceria and containing rhodium or nickel or a mixture of rhodium and nickel.  
     
     
         5 . The reactor as claimed in  claim 4  wherein ceria coating comprises about 15 to about 20 percent by weight of said ceramic foam monolith material.  
     
     
         6 . The reactor as claimed in  claim 4  wherein said rhodium or nickel or mixture of nickel and rhodium is about 2 to about 4 weight percent of said ceramic foam monolith  
     
     
         7 . The reactor as claimed in  claim 1  comprising a plurality of said ceramic foam disk impregnated with a catalytic material and a plurality of blank ceramic foam disks.  
     
     
         8 . The reactor as claimed in  claim 1  wherein said at least one blank ceramic foam disk is selected from the group consisting of alumina, zirconia, cordierite or mixtures thereof.  
     
     
         9 . The reactor as claimed in  claim 1  further comprising a quenching system.