Bonnot Catalyst Extruder
| Brand | Bonnot |
|---|---|
| Origin | USA |
| Manufacturer Type | Authorized Distributor |
| Product Origin | Imported |
| Model | Catalyst Extruder |
| Pricing | Available Upon Request |
Overview
The Bonnot Catalyst Extruder is a precision-engineered single-screw extrusion system designed specifically for the pharmaceutical, petrochemical, and catalysis industries to convert pre-nixed catalyst pastes—particularly dehydrogenation catalysts—into uniform, dimensionally stable cylindrical extrudates. Operating on the principle of controlled shear and axial compression within a heated barrel and screw assembly, this extruder enables reproducible formation of catalytic pellets with consistent diameter (typically 1.0–3.0 mm), length-to-diameter ratio, surface finish, and green strength prior to calcination or activation. Its robust mechanical architecture ensures minimal thermal degradation and mechanical breakdown of sensitive catalytic precursors during processing, supporting high batch-to-batch repeatability required in GMP-compliant catalyst manufacturing environments.
Key Features
- Stainless-steel barrel and screw with precision-machined flight geometry optimized for low-shear paste conveyance and minimal residence time variation
- Adjustable die plate configuration accommodating multiple extrudate diameters (1.0 mm, 1.5 mm, 2.0 mm, and 2.5 mm) via interchangeable hardened steel dies
- Variable-speed DC drive system enabling precise control over extrusion rate (0.5–15 kg/h range typical for lab-scale operation)
- Water-jacketed barrel with independent PID temperature zones (ambient to 120 °C) for thermal management of heat-sensitive catalyst formulations
- Integrated vacuum venting port for moisture and volatile removal during extrusion—critical for maintaining binder integrity and preventing blistering
- Modular design supporting rapid cleaning and tooling changeover; compliant with ASME BPE surface finish standards (Ra ≤ 0.8 µm) for pharmaceutical-grade use
Sample Compatibility & Compliance
The Bonnot Catalyst Extruder processes a broad spectrum of catalyst precursor materials—including alumina-, silica-, and zeolite-based pastes containing metal promoters (e.g., Pt, Cr, Ni), organic binders (e.g., methylcellulose, PVA), plasticizers, and pore-forming agents. It accommodates feedstock viscosities ranging from 10⁴ to 10⁶ mPa·s at shear rates of 1–10 s⁻¹. The system meets structural requirements outlined in ASTM D4169 for equipment used in catalyst pellet production and supports documentation traceability aligned with FDA 21 CFR Part 11 when integrated with validated data acquisition systems. All wetted parts conform to USP Class VI biocompatibility testing and are compatible with clean-in-place (CIP) protocols under ISO 14644-1 Class 7 cleanroom conditions.
Software & Data Management
While the base configuration operates via analog panel controls, optional digital instrumentation packages include a touchscreen HMI with real-time logging of screw speed, barrel zone temperatures, motor torque, and extrudate mass flow (via load-cell-integrated conveyor). Data export is supported in CSV and XML formats for integration into LIMS or MES platforms. Audit trail functionality—enabling user login tracking, parameter change history, and electronic signature capture—is available under IQ/OQ validation support packages compliant with ICH Q7 and Annex 15 guidelines. Firmware updates are delivered via secure USB interface with SHA-256 checksum verification.
Applications
- Production of cylindrical extrudates for Pt-Sn/Al₂O₃ dehydrogenation catalysts used in propane-to-propylene processes
- Formulation of V₂O₅–WO₃/TiO₂ selective catalytic reduction (SCR) catalysts for NOₓ abatement
- Manufacturing of Ni–Mo/Al₂O₃ hydrodesulfurization (HDS) catalyst precursors with controlled macroporosity
- R&D-scale development of structured catalysts for microreactor integration and monolithic substrate coating
- Quality assurance testing of binder rheology and paste extrudability prior to full-scale production line deployment
FAQ
What types of catalyst feedstocks are compatible with the Bonnot Catalyst Extruder?
It accepts aqueous and solvent-based catalyst pastes containing inorganic oxides, transition metal compounds, polymeric binders, and fugitive pore formers—provided viscosity and particle loading fall within defined process windows.
Can the extruder be validated for GMP manufacturing?
Yes; IQ/OQ documentation templates, calibration records, and FAT/SAT protocols are provided. Integration with 21 CFR Part 11-compliant software requires optional digital upgrade package.
Is technical support available for process optimization?
Bonnot-authorized distributors offer application engineering services including paste formulation review, die selection guidance, and extrusion parameter mapping studies.
What maintenance intervals are recommended?
Screw/barrel inspection every 500 operational hours; die cleaning after each batch; full lubrication and torque verification per ASTM E2917 quarterly maintenance schedule.
Does the system support nitrogen purging for oxygen-sensitive catalysts?
An optional inert gas purge manifold (with flowmeter and pressure regulator) can be factory-installed to maintain <10 ppm O₂ in the extrusion chamber.
