A process for preparing a syngas from a methane comprising gas includes reacting the methane comprising gas with an oxidising gas at an operating temperature in the range of 1150 to 1370° C. by means of non-catalytic partial oxidation. A hot raw syngas mixture having a methane content higher than the methane content in a state of thermodynamic equilibrium at the operating temperature applied is passed through a bed of methane oxidation catalyst for oxidising methane with steam formed in the non-catalytic POX into carbon monoxide and hydrogen. The methane oxidation catalyst has at least one catalytically active metal supported on a refractory oxide support material where soot particles present in the hot raw syngas mixture are retained. The retained soot particles are converted to carbon monoxide. Soot depleted syngas is recovered in a state of thermodynamic equilibrium.

Redox catalysts are provided for “low-temperature” methane partial oxidation in absence of gaseous oxidants. Methods of converting the methane to syngas using the catalysts are also provided. In some aspects, the conversion takes place at temperatures of about 400° C. to about 950° C. The methods can be used to convert methane to syngas containing carbon monoxide and hydrogen gas. In some aspects, the methods are carried out in a fixed bed reactor with reverse flow.

The invention relates to a structured catalyst for catalyzing steam methane reforming reaction in a given temperature range T upon bringing a hydrocarbon feed gas into contact with the structured catalyst. The structured catalyst comprises a macroscopic structure, which comprises an electrically conductive material and supports a ceramic coating. The macroscopic structure has been manufactured by 3D printing or extrusion and subsequent sintering, wherein the macroscopic structure and the ceramic coating have been sintered in an oxidizing atmosphere in order to form chemical bonds between the ceramic coating and the macroscopic structure. The ceramic coating supports catalytically active material arranged to catalyze the steam methane reforming reaction, wherein the macroscopic structure is arranged to conduct an electrical current to supply an energy flux to the steam methane reforming reaction. The invention moreover relates to methods of manufacturing the structured catalyst and a system using the structured catalyst.

A process for removing hydrocarbons from a feed stream containing hydrocarbons includes introducing ozone to the feed stream to produce an ozone doped stream containing ozone and hydrocarbons, and contacting the ozone doped stream with a supported metal catalyst at a temperature of from 100° C. to 300° C. to produce a treated stream, wherein the supported metal catalyst comprises iron supported on a support selected from aluminosilicates, silica-aluminas, silicates and aluminas. A process for removing NOx from a feed stream containing NOx, and an apparatus for removing hydrocarbons and/or NOx from a feed stream containing hydrocarbons and/or NOx are also provided.

Described is a method for the preparation of a reforming catalyst. The method comprises: (a) depositing a metal precursor on a porous support by wet impregnation, wherein the porous support is selected from the group consisting of a fumed silica, a fumed metal oxide, and combinations thereof; (b) drying the porous support after depositing the metal precursor to form a powder; (c) adding additional porous support to the powder to form a diluted powder; and (d) pressing the diluted powder to form pellets.

Provided herein are catalyst materials and processes for processing hydrocarbons. For example, doped ceria-supported metal catalysts are provided exhibiting good activity and stability for commercially relevant DRM process conditions including low temperature and long term operation.

A highly compact heat integrated fuel processor, which can be used for the production of hydrogen from a fuel source, suitable to feed a fuel cell, is described. The fuel processor assembly comprises a catalytic reforming zone (29) and a catalytic combustion zone (28), separated by a wall (27). Catalyst able to induce the reforming reactions is placed in the reforming zone and catalyst able to induce the combustion reaction is placed in the combustion zone, both in the form of coating on a suitable structured substrate, in the form of a metal monolith. FeCrAIY steel foils, in corrugated form so as to enhance the available area for reaction, can be used as suitable substrates. The reforming and the combustion zones can be either in rectangular shape, forming a stack with alternating combustion/reforming zones or in cylindrical shape forming annular sections with alternating combustion/reforming zones, in close contact to each other. The close placement of the combustion and reforming catalyst facilitate efficient heat transfer through the wall which separates the reforming and combustion chambers.

The invention concerns particles which may include a catalytically active component, in the form of a three-dimensional ellipsoidal shape having three major axes at least two of which axes are of different lengths. Beds of such particles are useful for forming particle beds through which a fluid may flow.

The present invention relates to a monolith catalyst for carbon-dioxide/methane reforming and a method of manufacturing the same, and more particularly to a novel monolith catalyst for a reforming reaction having improved thermal durability, configured such that a sintering inhibiting layer is formed by coating the surface of a monolith support with at least one element selected from the group consisting of Group 2, 3, 6, 13, 15 and 16 elements among elements in Period 3 or higher and an active catalyst layer is formed on the sintering inhibiting layer, thereby preventing carbon deposition and catalyst deactivation due to deterioration even upon reaction at high temperatures.

A partial oxidation process of hydrocarbons is provided, including bringing an inlet gas into contact with a catalyst, the inlet gas including a hydrocarbon raw material gas and a hydrogen chloride gas, wherein the catalyst includes a catalyst material including palladium (Pd), which catalyst material is supported on a carrier including cerium oxide (CeO.sub.2) and an amount of catalyst material supported on the carrier is 2 wt % to 10 wt % based on a total weight of the catalyst.