Blended catalyst with improved performance

A method for forming a partial oxidation catalyst element comprising the steps of:

• a) forming a calcined catalytic component by combining a catalytically active metal selected from the group consisting of Ni, Rh, Pt, Pd, Ir, Au, and combinations thereof with a first support material to form a mixture, wherein the first support material comprises particles having an average particle diameter of less than 20 microns, and calcining said mixture to form the calcined catalytic component;
• b) forming a calcined support component by calcining a second support material, not containing the catalytically active metal, wherein the second support material comprises particles having an average particle diameter of less than 20 microns;
• c) forming a catalyst material by mixing together said calcined catalytic component and said calcined support component, wherein the catalyst material contains less than 20% of the calcined catalytic component by weight;
• and
• d) applying said catalyst material to a substrate configured for gas flow therethrough, thereby forming the partial oxidation catalyst element.