Catalyst development
from Lab to Launch
Your dedicated partner for custom catalyst formulation, process development, and scale-up, transforming your breakthrough chemistry through commercially viable catalyst solutions.
From catalyst design to commercial-ready production
Our catalyst development service is an end-to-end partnership designed to bridge the gap from a proven lab-scale formulation to a de-risked, pilot-ready catalyst. We apply deep expertise in materials science and catalyst engineering to help you optimize performance, validate manufacturability, and accelerate your path to market.
Catalyst Design and Formulation
Translate your technical innovation into a novel catalyst formulated for your exact needs. The design process focuses on optimizing active metals, promoters, and supports to deliver maximum performance, selectivity, and stability, all validated by advanced characterization.
Materials Synthesis
Bring your catalyst design from concept to reality. Flexible synthesis methods, including co-precipitation, hydrothermal synthesis, impregnation, and ion exchange, enable rapid prototyping and production of your novel materials at the bench and pilot scales.
Advanced Catalyst Forming
Transform your active powder into robust, reactor-ready forms engineered for your specific process. This includes forming via extrusion, tableting, and granulation, or advanced coating onto structures like monoliths, foams, and plates.
Process Optimization and Scale-Up
Bridge the gap from lab scale to pilot production. We scale catalyst forming, coating, and custom powders from grams to metric-ton batches, establishing the quality controls needed for a repeatable, de-risked path to commercialization.
A balanced approach to catalyst development
A successful commercial catalyst is an engineered system. It must balance three critical areas of performance. Our holistic development process is designed to find the optimal balance for your specific application.
Activity & Selectivity
Maximizing performance and product purity through high-dispersion active sites and specialized promoter materials.
Mass Transfer
Engineering the ideal form factor, microstructure, and porosity to meet your reactor’s specific needs for mass transfer and pressure drop.
Mechanical Stability
Enhancing mechanical strength and attrition resistance through tailored binder and additive systems for long-term stability.
Our lab and production capabilities are designed to balance these practical needs, delivering optimized powders, granules, extrudates, monoliths, and tablets for your chemical process.
Deep technical expertise in catalyst systems.
Our team, with over 50 years of combined catalyst expertise and specialized facilities, is equipped to handle your most complex catalyst challenges.
Material & Support Expertise
We have a broad range of catalyst materials expertise, including:
Active Metals
Extensive experience with base metals such as nickel (Ni), cobalt (Co), copper (Cu), iron (Fe), and manganese (Mn), as well as key precious metals like platinum (Pt), palladium (Pd), rhodium (Rh), and ruthenium (Ru).
Catalyst Supports
We work with all common catalyst supports, including alumina, silica, titania, zirconia, ceria, zeolites, and others.
Specialty Materials
Our team has deep knowledge of specialty materials, including Zeolites, Aluminosilicates, MOFs, Oxides, Carbides, and Nitrides.
Syngas & Reforming
Steam Methane Reforming (SMR), Dry Methane Reforming (DMR), Autothermal Reforming (ATR), and Catalytic Partial Oxidation (CPOx)
Synthetic Fuels
Fischer-Tropsch Synthesis (FTS) and Methanol Synthesis
Chemical Synthesis
Methanation and Hydroformylation
Syngas Conditioning
Water-Gas Shift (WGS) and Reverse-Water-Gas Shift (rWGS)
Key Reaction Expertise
We have deep experience supporting major catalytic pathways, including:
More than a supplier: Your scale-up partner in
catalyst innovation.
Flexibility & Speed
Move fast with rapid iteration cycles and agile custom development in months, not years.
Partnership Approach
We’re not just a supplier. We’re an extension of your team, working as your key development partner to deliver tailored catalyst solutions.
Deep Technical Expertise​
30+ year legacy, with PhD-level expertise across high-temperature catalysis, advanced materials development, catalyst formulation, ceramic supports, and process optimization.
Proven Commercialization Pathway
End-to-end manufacturing capabilities from concept to commercialization, with seamless handoffs to our network at scale.
Specialized infrastructure. Flexible facilities.
Leveraging rapid prototyping and flexible manufacturing to design, develop, and manufacture novel catalysts.
Flexible synthesis equipment, including co-precipitation and hydrothermal autoclave reactors.
Process capabilities for impregnation, ion exchange, and high shear mixing.
Treatment facilities for drying, calcination, and controlled atmosphere reduction.
Forming equipment, including extrusion, tableting, and high-intensity granulation.
Advanced coating lines for wash coating, spin coating, and aerosol spray coating.
Expertise in processing powders, granules, extrudates, tablets, and coated structures.
Physical Analysis: Surface area analyzers (BET), porosimeters, and particle size analyzers.
Chemical & Phase Analysis: XRD, SEM/EDS, and XRF for elemental and phase identification.
Performance Analysis: TGA/DTA and chemisorption (TPD, TPR, TPO) units.
More than development.
Your integrated partner.
Bridge the gap from a proven catalyst to a validated product. Our development process flows directly into pilot-scale manufacturing and investor-ready validation, all under one roof.
Pilot-Scale Toll Manufacturing
Once your formulation is proven, scale it with confidence. We offer agile toll manufacturing of your custom catalyst extrudates, coated structures, and powders in flexible 50 kg – 1 metric ton batches to de-risk commercialization.
Validation & Testing
Validate your catalyst’s performance with investor-ready data. We provide rigorous testing in our multi-reactor facility, offering accelerated aging, lifetime testing, kinetic modeling support, and full materials characterization.
Driving innovation in emerging energy industries
Our custom catalyst development services are the engine for breakthroughs in the clean energy and specialty chemical sectors.
How we partner from Lab to Launch.
A partnership built on technical depth and transparency. Our proven Lab to Launch process gives you dedicated access to an expert team and a data-driven workflow focused on your commercial milestones.
Grow with a partner that protects your quality, protects your process, and protects your IP.
Proven expertise. Trusted partners.
Trusted by Fortune 500 companies, U.S. National Laboratories, and custom catalyst innovators worldwide.
From vision to reality.
Nexceris commercialized and successfully exited the Li-ion Tamer® business through its acquisition by Honeywell.
Ready to accelerate
your custom catalyst project?
Let’s explore how we can help you scale faster and smarter, from Lab to Launch.
