Process for the catalytic conversion of methane or natural gas to syngas or a mixture of carbon monoxide and hydrogen

Abstract

A process for catalytic conversion of methane or natural gas to syngas using a supported catalyst containing oxides of nickel and cobalt with of without noble metals. Efficiency of the catalytic process is increased by simultaneously carrying out an exothermic oxidation reaction and an endothermic steam and carbon dioxide reforming reaction over the supported catalyst. The catalyst is prepared by depositing oxides of nickel and cobalt, with or without noble metals, on a sintered low surface area porous inert support. Surface of the support is precoated with an oxide of Be, Mg, Ca or a mixture thereof so that a protective layer of alkaline earth oxide is formed between the oxides of nickel and cobalt and the support, and hence, direct chemical interactions between the oxides of nickel and cobalt and reactive components of the support, which leads to formation of catalytically inactive binary oxide phases, are avoided.