Compact partial oxidation reactor assemblage with fast start-up capability

A process for forming a mixture of hydrogen and carbon monoxide by a catalytic partial oxidation reaction in a reactor containing both an electrically heated catalyst and a noble metal washcoated metal monolith catalyst comprising:

• a) providing a feed gas mixture comprising oxygen containing gas and a hydrocarbon feedstock selected from the group consisting of methane, natural gas, LPG, naphtha, gasoline and diesel oil, said mixture being characterized by an atomic carbon to atomic oxygen ratio of between 0.7 to 1.0;
• b) passing said feed gas mixture at room temperature through a heat exchanger to be preheated, before being introduced to the reactor, by a hot product gas stream generated by the partial oxidation reaction;
• c) providing a reactor containing a first catalyst structure comprising a supported noble metal catalyst washcoated on a first metal monolith;
• d) providing an electrically heated catalyst installed in front of said first catalyst structure, the electrically heated catalyst comprising a supported noble metal catalyst washcoated on a second metal monolith having welded electrical rods at both ends within said reactor for igniting the partial oxidation reaction to produce an ignited feed gas mixture;
• e) passing said ignited feed gas mixture through said first catalyst structure so as to convert said feed gas mixture to hydrogen and carbon monoxide and heat the hydrogen and carbon monoxide by the heat of the partial oxidation reaction, said heated hydrogen and carbon monoxide comprising the hot product gas stream;
• f) passing said hot product gas stream through said heat exchanger to provide heat to said feed gas mixture.