In this research, the motion and distribution characteristics of waste palladium catalysts in a compound dry separator were investigated by DEM-CFD. Based on the actual separation experiments, the effects of various process parameters on separation performance were studied. The significance of both single factor and factor combination were analyzed. In addition, parametric majorization and further experimental verification were conducted. The results showed that, in the separation process, the rod-shaped catalysts are mainly distributed in backplane region and move along the backplane with a gradual weakening spiral motion, and the spherical catalysts are distributed in lattice-bar region and directly move to the discharge end. The maximum efficiency E-f is obtained when the amplitude (AM) is 3.0-3.5 mm, frequency (FR) is 32-38 Hz, gas velocity (GV) is around 1 m/s, and lateral-gradient (theta) is 4 degrees-6 degrees. The influence degree of various factors on E-f follows the order: FR > theta > AM > GV. An actual separation efficiency was 99.61% when GV = 0.96 mm, FR = 35.98 Hz, AM = 3.28 mm and theta = 5.64 degrees, indicating a satisfactory separation performance of waste palladium catalysts using a compound dry separator. (C) 2020 The Society of Powder Technology Japan. Published by Elsevier B.V.