Bimetallic catalyst for catalytic partial oxidation of hydrocarbons

Abstract

A bimetallic catalyst composition containing a mesh substrate having supported thereon an alumina washcoat on which are impregnated bimetallic particles of rhodium and ruthenium in specified amounts. A process for the catalytic partial oxidation of a hydrocarbon, such as methane or natural gas, involving contacting the hydrocarbon with an oxidant in the presence of the aforementioned bimetallic catalyst under reaction conditions sufficient to produce synthesis gas, that is, to a mixture of hydrogen and carbon monoxide.

1 .- 14 . (canceled) 
     
     
         15 . A catalyst composition comprising a mesh substrate having supported thereon an alumina washcoat, on which are impregnated bimetallic particles of rhodium and ruthenium; wherein the rhodium is present in an amount equal to or greater than about 5 percent and in an amount equal to or less than about 54 percent, by weight, based on a total weight of the rhodium-ruthenium bimetallic particles; and wherein the ruthenium is present in an amount equal to or greater than about 46 percent and an amount equal to or less than about 95 percent, by weight, based on by the total weight of the rhodium-ruthenium bimetallic particles. 
     
     
         16 . The catalyst composition of  claim 15  wherein the bimetallic particles of rhodium and ruthenium have an average particle size ranging from 5.0 nm to 5.4 nm with a standard deviation no greater than 2.0 nm. 
     
     
         17 . The catalyst composition of  claim 15  wherein the composition contains essentially no crystalline phase of rhodium oxide, ruthenium oxide, or mixed rhodium-ruthenium oxides. 
     
     
         18 . The catalyst composition of  claim 15  wherein the mesh substrate has an ultra-short-channel-length ranging from 25 microns (μm) to 500 μm. 
     
     
         19 . The catalyst composition of  claim 18  wherein the mesh substrate comprises from about 100 to about 1,000 or more flow channels per square centimeter. 
     
     
         20 . The catalyst composition of  claim 18  wherein the mesh substrate is configured with a plurality of channels or pores having a diameter ranging from about 0.25 millimeters (mm) to about 1.0 mm, with a void space greater than about 60 percent. 
     
     
         21 . The catalyst composition of  claim 15  wherein the mesh substrate is constructed from a metal or ceramic material. 
     
     
         22 . The catalyst composition of  claim 15  wherein the mesh substrate comprises a porous structured material having from about 5 to about 80 pores per inch, and a relative density, ranging from about 2 to about 15 percent, wherein relative density is taken as the density of the structured material divided by a density of solid parent material from which the structured material is constructed.