Lanthanide-promoted rhodium-containing supported catalysts that
are active for catalyzing the net partial oxidation of methane to CO and H2
are disclosed, along with their manner of making and high efficiency processes
for producing synthesis gas employing the new catalysts. A preferred catalyst comprises
highly dispersed, high surface area rhodium on a granular zirconia support with
an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally
conditioned during catalyst preparation. In a preferred syngas production process
a stream of methane-containing gas and O2 is passed over a thermally
conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact
time reactor to produce a mixture of carbon monoxide and hydrogen.