BASF Starts Up World First Industrial-Scale 3D Printed Catalyst Plant

BASF has started up what it describes as the worlds first production plant for 3D printed catalysts at its Ludwigshafen site in Germany. The facility is based on the companys X3D technology.

Advanced Catalyst Geometries

BASF says X3D enables catalyst geometries that combine high mechanical stability with an open structure. This design reduces pressure drop in reactors while increasing catalytically active surface area, allowing higher reactor throughput, improved product quality, and lower energy consumption compared with conventional catalysts.

Already Proven in Production

The chemicals group has supplied these catalysts to production plants for several internal and external customers for years. One example: Chinese chemical company An Hui Jintung filled its production plant with X3D sulfuric acid catalysts in 2025.

The plant started up smoothly, and plant performance has significantly improved compared to before. Production achieved a record high, the company reported.

Broad Application Range

The technology can be applied to a broad range of catalyst materials, including precious metal catalysts, base metal catalysts, and various support materials.