A critical requirement in DOEs efforts to recycle, reuse, and dispose of materials from its decontamination and decommissioning activities is the design of a robust system to process a wide variety of bulk solid feeds. The capability to process bulk solids will increase the range of materials and broaden the application of Catalytic Extraction Processing (CEP). The term bulk solids refers to materials that are more economically fed into the top of a molten metal bath than by submerged injection through a tuyere. Molten Metal Technology, Inc. (MMT) has characterized CEPs ability to process bulk solid feed materials and has achieved significant growth in the size of bulk solid particles compatible with Catalytic Extraction Processing. Parametric experimental studies using various feed materials representative of the components of various DOE waste streams have validated design models which establish the reactor operating range as a function of feed material, mass flow rate, and particle size. MMT is investigating the use of a slurry system for bulk solid addition as it is the most efficient means for injecting soils, sludges, and similar physical forms into a catalytic processing unit. MMT is continuing to evaluate condensed phase product removal systems and alternative energy addition sources to enhance the operating efficiency of bulk solids CEP units. A condensed phase product removal system capable of on-demand product removal has been successfully demonstrated. MMT is also investigating the use of a plasma arc torch to provide supplemental heating during bulk solids processing. This comprehensive approach to bulk solids processing is expected to further improve overall process efficiency prior to the deployment of CEP for the recycle, reuse, and disposal of materials from DOE decontamination and decommissioning Activities.