Patent ID: 7981397

Claim:
A catalytic partial oxidation process, said process comprises passing a feed stream through a reactor having at least a first reaction zone and subsequently a second reaction zone, wherein the first reaction zone containing a first catalyst having a first surface area and a first thermal conductivity, the first catalyst comprising a first metal in reduced form or oxidized form or in an alloy and either being supported on a first carrier or unsupported, wherein, if supported, said first carrier comprises one or more metallic substances with a high thermal conductivity and the first metal is electroplated or diffusingly coated on the first catalyst carrier, wherein the first surface area is less than about 1.0 square meter per gram (m 2 /g); and the second reaction zone contains a second catalyst having a second surface area and a second thermal conductivity, the second catalyst comprising a second metal supported on a carrier to produce an effluent stream comprising carbon monoxide and hydrogen; wherein the feed stream comprises (a) a hydrocarbon feedstock, and (b) oxygen or an oxygen containing mixture; wherein the first surface area of the first catalyst is lower than the second surface area of the second catalyst; wherein the first thermal conductivity of the first catalyst is at least 0.05 cal/cm 2 /cm/second/° C. at operating temperatures; wherein the first thermal conductivity of the first catalyst is higher than the second thermal conductivity of the second catalyst; and wherein a pressure in said reactor is between about 600 kPa and about 7,500 kPa.