초록 ▼

This invention provides a catalyst and a process for the catalytic partial oxidation of a hydrocarbon feedstock by contacting a feed stream including a hydrocarbon feedstock and an oxygen-containing gas with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to pro

This invention provides a catalyst and a process for the catalytic partial oxidation of a hydrocarbon feedstock by contacting a feed stream including a hydrocarbon feedstock and an oxygen-containing gas with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream including carbon monoxide and hydrogen. The process of this invention is characterized by using a porous catalyst containing rhodium, such as rhodium gauze or rhodium felt.

대표청구항 ▼

1. A process for the catalytic partial oxidation of a light hydrocarbon feedstock, comprising: contacting a feed stream comprising a light hydrocarbon feedstock and an oxygen-containing gas with a porous bulk metal catalyst at conversion-promoting conditions effective to produce an effluent stream

1. A process for the catalytic partial oxidation of a light hydrocarbon feedstock, comprising: contacting a feed stream comprising a light hydrocarbon feedstock and an oxygen-containing gas with a porous bulk metal catalyst at conversion-promoting conditions effective to produce an effluent stream comprising carbon monoxide and hydrogen; wherein the catalyst comprises a metal cloth; wherein the metal comprises at least 90 wt % rhodium; and wherein said conversion-promoting conditions include passing said feed stream over said catalyst at a gas hourly space velocity of at least about 60,000 hr −1.2. The process of claim 1, wherein carbon monoxide is produced at a carbon selectivity of at least about 80%.3. The process of claim 1, wherein hydrogen is produced at a hydrogen selectivity of at least about 70%.4. The process of claim 1, wherein hydrogen is produced at a hydrogen selectivity of about 100% and the hydrocarbon conversion is at least about 97%.5. The process of claim 1, wherein the catalyst comprises a gauze consisting essentially of rhodium.6. The process of claim 1, wherein the catalyst comprises a felt consisting essentially of rhodium.7. The process of claim 1, further comprising pretreating the catalyst by exposure to air under conditions sufficient to oxidize the catalyst.8. The process of claim 7 wherein the conditions include a temperature of about 300° C. to about 1200° C.9. The process of claim 8 wherein the conditions include a temperature of about 900° C. to about 1000° C.10. The process of claim 7 wherein the catalyst is pretreated for a duration of time of about one half hour to about four hours.11. The process of claim 1, wherein the catalyst has a catalytic half-life of at least about six months.12. The process of claim 11 wherein the catalyst has a catalytic half-life of from about six months to about 2 years.13. The process of claim 1, further comprising preheating said feed stream above about 30°C.14. The process of claim 13 wherein the feed stream is preheated to a temperature between about 50° C. and about 700° C.15. The process of claim 14 wherein the feed stream is preheated to a temperature between about 400° C.-500° C.16. The process of claim 1 wherein maintaining the reaction zone further comprises maintaining pressure in said reaction zone between about 500 kPa and about 3000 kPa.17. The process of claim 1 wherein said feed stream comprises a methane to oxygen molar ratio of about 1.5:1 to about 2.2:1.18. The process of claim 1 wherein the hydrogen feedstock comprises at least about 50% by volume methane.19. The process of claim 1, wherein contacting the feed stream with the catalyst comprises passing the feed stream over the catalyst at a space velocity from about 150,000 to about 10,000,000 hr−1.20. A process for the catalytic partial oxidation of a light hydrocarbon feedstock, comprising: contacting a feed stream comprising a light hydrocarbon feedstock and an oxygen-containing gas feed stream with a catalyst at conversion-promoting conditions effective to produce an effluent stream comprising carbon monoxide and hydrogen; wherein the catalyst consists of at least 90 wt % rhodium; wherein carbon monoxide is produced at a carbon selectivity of at least about 80%; and wherein hydrogen is produced at a hydrogen selectivity of at least about 60%; and wherein said conversion-promoting conditions include passing said feed stream over said catalyst at a gas hourly space velocity of at least about 60,000 hr −1.21. The process of claim 20 wherein the catalyst comprises a felt.22. The process of claim 20 wherein the catalyst comprises a gauze.23. The process of claim 20 wherein the hydrocarbon feedstock comprises at least about 50% methane by volume.24. A process for the catalytic partial oxidation of a light hydrocarbon feedstock, comprising: (a) preheating a feed stream comprising a light hydrocarbon feedstock and oxygen gas to at least about 350° C.; (b) passing the feed stream over a catalyst consisting of at least 90 wt % rhodium, at a space velocity from about 150,000 to about 10,000,000 hr −1at conversion-promoting conditions comprising a pressure from about 500 kPa to about 3000 kPa wherein the conditions are effective to produce an effluent stream comprising carbon monoxide and hydrogen; wherein the catalyst is selected from the group consisting of rhodium felt and rhodium gauze, the carbon monoxide is produced at a carbon selectivity of at least about 80%, and the hydrogen is produced at a hydrogen selectivity of at least about 60%.