A multistage catalytic partial oxidation (CPO) process for oxidizing a
hydrocarbon feedstream comprising C.sub.1 -C.sub.4 hydrocarbons, with an
oxygen-containing feedstream to produce a product comprising CO and
H.sub.2, also known as synthesis gas or syngas. The process employs a CPO
catalyst, and controlled process features, including: (A) the total oxygen
requirement for the process is introduced incrementally, in more than one
reaction stage, using an oxygen-containing feedstream at more than one
feed point in the process, each stage including a catalyst; (B) the
oxygen-containing feedstream, hydrocarbon feedstream and, in reaction
stages after the first of said multiple stages, the intermediate product
produced in the prior stage, are mixed for a period of time, after they
are brought into contact with one another, of less than about 1
millisecond to form a substantially uniform mixture, wherein the mixture
is then contacted with the catalyst; (C) the oxygen-containing feedstream
and the hydrocarbon feedstream are preheated prior to entry into the first
stage, to a temperature of from about 450.degree. C. to less than about
1,000.degree. C.; and (D) the mixture temperature of the product in each
stage following the first stage is from greater than about 600.degree. C.
to less than about 1,000.degree. C. Preferably, the process comprises less
than or equal to about five stages, the first stage preheat temperature
recited in step (C) is greater than about 550.degree. C. and the mixture
temperature of the product in each stage following the first stage is at
least 700.degree. C.
