Thermal shock resistant catalysts for synthesis gas production

Syngas catalyst compositions supported on refractory ceramic textiles and fibrous ceramic composite catalysts are disclosed, together with their methods of making and use for catalyzing syngas production from methane by a net partial oxidation reaction. In certain preferred embodiments the active catalyst material is Rh, Ni, Cr, or combinations thereof. The ceramic textiles may be arranged in a variety of 3-D forms, such as Nextel™ or various woven or braided meshes and layers. The ceramic textile is easier to scale up to commercial reactor dimensions than the conventional foams and monoliths comprising ceramics and metals. Tolerance to thermal expansion and thermal heat integration are also improved by the new catalysts. A synthesis gas production process employs a new ceramic composite catalyst in a fixed reaction zone maintained at conversion-promoting conditions effective to produce an effluent …