X3D®
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:
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
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.
Estimate your plant's annual caustic soda and cost savings from the higher SO2 conversion enabled by X3D® catalyst beds.
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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.
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.
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.
