A multilayered catalyst configuration and methods for syngas production

A catalyst composition comprising a first layer of a catalytically active metal selected from the group consisting of nickel, cobalt, iron, platinum, palladium, iridium, rhenium, ruthenium, rhodium, osmium and combinations thereof dispersed on an inert monolithic carrier support having a honeycomb shape and is made from a material selected from the group consisting of alumina, mullite, zirconia, partially stabilised zirconia, ceria, silica, silicon carbide, silicon nitride, silicon nitride ceramic, aluminium nitride, boron nitride, aluminosilicate magnesium aluminosilicates, a combination of magnesium aluminosilicates and aluminosilicate, and mixtures of these and a second layer of a reduced metal catalyst consisting essentially of a transition metal selected from the group consisting of nickel, cobalt, iron, platinum, palladium, iridium, rhenium, ruthenium, rhodium, osmium, and combinations thereof supported on or in a stable inorganic metal oxide selected from the group consisting of oxides comprising one or more cations selected from groups IA, IA, lIlA and IVA of the Periodic Table of the Elements, the transition metals and mixtures of these washcoated on a support. The catalyst is for the partial oxidation of hydrocarbons to produce hydrogen and carbon monoxide, by contacting a mixture of a hydrocarbon containing feed gas and an oxygen containing feed gas with the catalyst.