Partial oxidation of methane to synthesis gas in a dual catalyst bed system combining irreducible oxide and metallic catalysts

Operation of partial oxidation of methane to synthesis gas over yttrium-stabilized zirconia (YSZ) at very high temperatures (¿900°C) slightly improves the selectivity to synthesis gas, which is caused by some activity of YSZ for steam and dry reforming of methane. LaCoO3 perovskite is not active in methane reforming, but very active in deep oxidation. This perovskite can be reduced to a highly dispersed cobalt catalyst by CH4 at high temperatures (>900°C), which is very active in methane reforming. The dual bed concept combines these two catalysts and demonstrates that synthesis gas with an equilibrium composition can be produced at high GHSV. The exposure of metal catalyst to O2 in the second catalyst bed is avoided because oxygen is converted completely in the first catalyst bed. Therefore, deactivation of metal catalyst via evaporation of its volatile oxides can be prevented.