X3D®
X3D®: Discover our commercially proven catalyst shaping technology
With the X3D® technology, BASF extends its proven catalyst production expertise into additive manufacturing. By combining 3D printing with established production know‑how, X3D® enables reliable, scalable, and large‑volume supply for industrial applications. The technology delivers high reactivity, flexible catalyst design, and reduced pressure drop, lowering energy consumption. X3D® catalysts are produced at industrial scale at BASF’s Verbund site in Ludwigshafen, Germany.
BASF starts up the world’s first production plant for 3D-printed catalysts in Ludwigshafen
BASF started up the world’s first production plant for catalysts based on X3D® technology at its Ludwigshafen site. With the commissioning of this facility, BASF is scaling the additive manufacturing of catalysts to an industrial level and strengthening its leading role in innovative solutions for the chemical industry.
Learn more here.
Virtual Round Table
From reactor‑driven catalyst design to measurable efficiency gains in real plants: In April 2026, the X3D® Round Table showed how advanced catalyst shaping is already reducing pressure drop, improving performance, and supporting CO₂ reduction at industrial scale.
Key Facts
- Industrial scale production plant in Ludwigshafen
- Proven-track record in industrial plants since 2019
- Versatile technology that can be applied to a wide range of catalytic materials
- Possibility to customize catalysts to customers’ specific conditions and needs
Customer Success Story – commercially proven technology
Since 2019, BASF has been selling Sulfuric Acid catalyst O4-115 based on the X3D® technology. These shapes have been used in industrial plants with outstanding benefits for our customers.
In a sulfonation plant with 32 MTPD capacity*, one catalyst bed of 1.2 m³ was replaced with X3D® catalyst:
- Increased conversion: 1% higher yield which equals 1 MTPD* or 25,000 €/a
- Caustic soda saving: 162.4 tons/a, or 58,000 €/a
- Energy savings due to decreased pressure drop: 106 MW/a, or 18,000 €/a
Total savings: €100,000 per year
*Sulfuric acid equivalents
Since end of 2023, N2O abatement catalyst has been installed in a commercial Nitric acid plant for long-term operation, showing high N2O removal rates at low investment costs.
Full catalyst bed of 0.6m3 replaced with X3D® catalyst
- Savings: more than €3m per year
- Blower energy saving: ~100mbar (compared to extrudates)
- CO2 equivalents emission savings: >€3m/a (compared w/o abatement)
- Low outlet concentration of 80ppm at high pressure nitric acid plants
X3D® - Unlock Cost Savings and Sustainability
X3D® is an established shaping technology which will help you cut down costs and boost your sustainability goals:
Benefits of the X3D® technology come from intrinsic properties such a lower bulk density, improved mechanical stability, a faster prototyping, novel and tailored shapes, a lower pressure drop and improved geometric surface area.
We are proud that X3D® is already delivering a measurable competitive edge for our internal and external customers. With the start‑up of our commercial X3D® production plant in Ludwigshafen, we enable rapid access to customized catalysts at industrial scale. This helps our customers accelerate process optimization, boost production performance, and reduce CO₂ emissions, supporting their sustainability goals without compromising throughput.
