Abstract: Embodiments include a method and apparatus for converting a hydrocarbon and oxygen feed stream to a product stream such as syngas, including multiple serially aligned reaction zones and multiple hydrocarbon feeds. The first reaction zone catalyzes the net partial oxidation of the feed hydrocarbon. The subsequent zones catalyze reactions such as the stream or dry reforming of hydrocarbons or the water gas shift reaction, depending on the stream composition in the vicinity of the zone, and the desired product stream composition.

Abstract: Controlled pore structure catalysts are disclosed that are active for catalyzing the partial oxidation of methane to CO and H2 and, advantageously, are capable of initiating the reaction without the need for an additional ignition source. A preferred catalyst comprises rhodium and samarium supported on an alumina or modified alumina support having certain surface area, pore volume, pore size and metal dispersion characteristics that permit light-off of the reaction at temperatures below 500° C. and with little or no use of an ignition agent. A method of partially oxidizing a light hydrocarbon to form synthesis gas, and a method of enhancing low-temperature light-off of the process are also described.

Abstract: The present invention is an improvement in the preparation of liquid hydrocarbons from natural gas/methane, oxygen and/or steam. In particular, the present invention relates to processes for the production of synthesis gas, reducing the oxygen concentration from the synthesis gas, and the production of liquid hydrocarbons using the oxygen reduced synthesis gas as a feedstock. More particularly, the present invention described herein identifies catalyst compositions, apparatus and methods of using such catalysts and apparatus for preparing liquid hydrocarbons via oxygen reduced synthesis gas all in accordance with the present invention.

Abstract: Catalysts comprising promoted cobalt-chromium oxide disposed on a lanthanide coated refractory support that are active for catalyzing the net partial oxidation of methane or natural gas to products containing CO and H2 are disclosed, along with short contact time processes employing the new catalysts for producing synthesis gas. Preferred promoters are rhodium and cerium, and a preferred lanthanide coating material is ytterbium.

Abstract: Combustion dispersed metal-metal oxide catalysts that are highly active for catalyzing the net partial oxidation of methane to CO and H2 are disclosed, along with their manner of making and processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises rhodium nanoparticles, with or without a rare earth promoter, that is deposited on &agr;-alumina by combusting a mixture of catalyst precursor materials and a flammable organic compound. In a preferred syngas production process a stream of reactant gas mixture containing methane and O2 is passed over the catalyst in a short contact time reactor to efficiently produce a mixture of carbon monoxide and hydrogen at superatmospheric pressures.

Abstract: A family of supported hexagonal phase mixed metal oxide catalysts are disclosed that have the general formula M2.5LnRh6O13 (expressed as atomic ratios), wherein M refers to Group II elements such as Mg, Ca, Ba, Sr and Be or a Group VIII transition metal that can exist in a +2 oxidation state, such as Ti, V, Mn, Fe, Co, Ni, Cu, Zn, Nb, Pd, Cd and Ta. Ln refers to the rare earth lanthanide group of elements, such as La, Yb, Sm and Ce. This family of catalysts demonstrate unexpected activity for efficiently catalyzing the net partial oxidation of methane in a short contact time reactor, with high selectivities for H2 product.

Abstract: Lanthanide-promoted rhodium-containing supported catalysts that are active for catalyzing the net partial oxidation of methane to CO and H2 are disclosed, along with their manner of making and high efficiency processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises highly dispersed, high surface area rhodium on a granular zirconia support with an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally conditioned during catalyst preparation. In a preferred syngas production process a stream of methane-containing gas and O2 is passed over a thermally conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact time reactor to produce a mixture of carbon monoxide and hydrogen.