Patent ID: 6971593

Claim:
A method for preparing an array of catalysis materials having a particle size distribution substantially within a predefined particle size range, the method comprising simultaneously crushing four or more catalysis materials in four or more spatially discrete crushing zones of a parallel crusher, respectively, each of the four or more catalysis materials comprising one or more materials selected from the group consisting of catalysts, catalyst precursors and catalyst supports, simultaneously sieving each of the four or more catalysis materials through a first primary sieve as they are being crushed or intermittently between repeated crushing steps, such that for each of the four or more catalysis materials, smaller, first-sieved particles pass through the primary sieve whereas larger unsieved particles are retained in the crushing zone for further crushing, and simultaneously sieving the first-sieved particles of each of the four or more catalysis materials through a second, secondary sieve, such that for each of the four or more catalysis materials, smaller, second-sieved particles pass through the secondary sieve whereas larger first-sieved particles are retained by the secondary sieve, whereby primary fractions of each of the four or more catalysis materials are formed, the primary fractions having a particle size distribution substantially within a particle size range ranging from about the mesh size of the secondary sieve to about the mesh size of the primary sieve.