Patent ID: 7230035

Claim:
A process for producing synthesis gas comprising: passing a hydrocarbon containing gas and an oxygen containing gas over a partial oxidation catalyst, under conditions effective to produce a gas stream comprising hydrogen and carbon monoxide, wherein the partial oxidation catalyst comprises a catalytic metal and a support material; wherein the partial oxidation catalyst includes a plurality of discrete structures, each comprising a core containing said support material and an outer region disposed on said core; wherein the plurality of discrete structures has an average size greater than 0.5 mm; wherein the outer region has an thickness of not more than 200 microns, and further wherein more than 60% of the catalytically active metal loaded on the discrete structure is located in the outer region further wherein the catalyst comprises a substantially blocked-micropore layer disposed between the outer region and the center of the core, said substantially blocked-micropore layer being either at the periphery of the core or extended substantially throughout the core.