A dual catalyst bed for the autothermal partial oxidation of methane to synthesis gas

Dual bed catalysts were found to produce high yields (>85%) of hydrogen from methane and air in a millisecond contact time reactor. The dual bed catalyst consisted of a 5 mm platinum combustion catalyst followed by a 5 mm nickel steam reforming catalyst. The platinum catalyst was used to totally oxidize approximately one-quarter of the methane feed to carbon dioxide and water. In the nickel catalyst, the carbon dioxide and water reformed the remaining methane to hydrogen and carbon monoxide. This process is favored at high flow rates, because the heat generated in the platinum catalyst is convected to the nickel catalyst at a higher rate. The heat delivered to the nickel catalyst favors the endothermic reforming reactions that generate the hydrogen and carbon monoxide.