Stabilized catalyst carrier and improved carrier configuration for catalytic combustion system

A process for the catalytically supported combustion of a gaseous carbonaceous fuel which comprises (a) forming a gaseous combustion mixture comprising the fuel and oxygen, (b) contacting the combustion mixture in a catalyst zone with at least one catalyst member comprising a carrier having a plurality of gas flow passages extending therethrough defined by channel walls and a catalyst material disposed on the channel walls and effective to catalytically support the combustion of the combustion mixture, under conditions suitable for catalyzed combustion of the combustion mixture, thereby effecting sustained combustion of at least a portion of the fuel in said combustion mixture without substantial formation of oxides of nitrogen, the carrier comprising a silica-alumina-magnesia material and prior to having the catalyst material disposed thereon, having been coated with a coating comprising alumina on the channel walls and having then been exposed to steam for a time and under conditions sufficient to induce the alumina to interact with the silica-alumina-magnesia material so that the carrier is stabilized against interaction with the catalyst material.