High energy level in situ attrition and break up of catalyst to maintain bed fluidization during high temperature operations

The prodn. of H2 and CO, involves contact in a reaction zone at high temp. in a fluidised bed of particulate solid catalyst and particulate solid diluent with a low mol. wt. hydrocarbon feed comprising methane, a steam feed and an oxygen feed to produce partial oxidn. and steam reforming reactions. Localised burning and excessive heat generation at the location of oxygen injection results from the reaction between the oxygen and hydrocarbon feeds which surface melts the solids particles and increases their intrinsic rate of agglomeration to produce dense, high-strength solids particles on repetitive passage thereof through the burning zone. The process improvement involves injecting the feeds into the fluidised bed at mechanical energy input level of 2000-6000 ft. lbs. per lb of oxygen, sufficient to balance the intrinsic rate of agglomeration, by fracturing and breaking up in situ the agglomerated catalyst to maintain the fluidised characteristics of the catalyst bed throughout the operational cycle.