Processing Systems for Catalysts
Produce high-performance heterogeneous catalysts with consistent quality, precise control and optimal efficiency. Hosokawa Micron designs advanced powder processing equipment for catalyst production—from drying and impregnating catalyst carriers to final shaping, compaction and size reduction. Our systems are engineered for reliable scale-up, solvent recovery and strict process control.
Catalyst manufacturers face increasing demands for reproducibility, process flexibility and sustainability. Our equipment supports key stages of catalyst preparation—whether you're processing slurries, pastes or dry powders—and enables accurate impregnation, uniform mixing and energy-efficient drying, all while ensuring batch-to-batch consistency and regulatory compliance.
Catalyst Carrier Preparation
Support materials (or carriers) are critical to the function of heterogeneous catalysts. The DMR flash dryer is ideal for processing wet materials such as slurries, filter cakes or pastes into free-flowing dry powders. Unlike traditional spray dryers, the DMR can handle high-solid content feeds—minimising energy use and reducing thermal stress on sensitive components.
The result: robust, dust-free catalyst carriers with excellent flowability, ready for impregnation or further downstream processing.
Impregnation with Active Components
Impregnation with active components requires precise liquid distribution and gentle handling. The Nauta® vacuum dryer ensures homogeneous impregnation of porous carriers—whether using incipient wetness, co-impregnation or deposition techniques. After impregnation, the same unit can be used to gently dry the material under vacuum, enabling efficient solvent recovery and thermal control.
Optional passivation steps—such as controlled oxygen introduction—can also be performed safely within the closed system.
Compaction & Shaping
Final catalyst properties depend heavily on mechanical strength, porosity and particle size distribution (PSD). Hosokawa Alpine offers milling and compaction technologies for densifying, downsizing or shaping catalysts. These systems are used to prepare catalysts in powder, pellet or tablet form—ready for fixed-bed or fluidised reactor use.
Test Before You Invest
Run trials with your own materials on production-scale equipment at our 2,000 m² Test & Process Development Centre in the Netherlands. Our experienced process specialists work with you to determine the optimal process, equipment or plant setup. We offer lab and production-scale trials, each supported by a detailed technical report covering setup, process parameters and performance insights—helping you choose the best solution with confidence.
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Talk to our experts
Looking to optimise catalyst production or improve energy efficiency in your process? Get in touch with our team to discuss how Hosokawa Micron’s advanced process systems can support your innovation and operational performance.
Sustainable process technologies
Hosokawa Micron B.V. is committed to sustainable and responsible process technology. Our ISO 14001 certification covers key environmental aspects such as air, soil, energy, waste, water, noise and hazardous substances. With an EcoVadis Silver Medal, we rank among the top 3% of EcoVadis-rated companies in the special machinery industry.
