An autothermal reactor and method for producing synthesis gas in which a
heated oxygen containing stream is expanded into a mixing chamber to
entrain a hydrocarbon containing stream to form a reactant stream without
reaction of the oxygen and hydrocarbon contents of the streams. The
reactant stream is reacted in a series of sequential catalytic reaction
zones to react the hydrocarbon and oxygen contained in the reactant
stream to form the synthesis gas. The sequential catalytic reaction zones
are configured such that an initial partial oxidation reaction occurs
that is followed by endothermic reforming reactions having ever
decreasing temperatures. The sequential catalytic reaction zones in which
the endothermic reforming reactions occur contain a precious metal
catalyst supported on ceramic supports that have successively greater
surface areas to compensate for the temperature decrease while remaining
stable and without a transform in state.