Catalytic partial oxidation processes and catalysts with diffusion barrier coating

A process for the production of synthesis gas from light hydrocarbons such as methane includes the net catalytic partial oxidation of a hydrocarbon feedstock by contacting a feed stream comprising the hydrocarbon feedstock and an O2-containing gas with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream of H2 and CO in a molar ratio of about 2:1. A preferred catalyst used in the process includes at least one catalytically active metal supported on a catalyst support comprising an aluminum-containing, oxide-dispersion-strengthened, alloy that has been treated to provide a protective oxide layer between the support and the catalytically active metal.