BASF has launched the world’s first production plant for 3D-printed catalysts in Ludwigshafen.

BASF has started operations at the world’s first production plant for catalysts based on X3D® technology at its Ludwigshafen site. With the commissioning of this facility, the company is scaling the additive manufacturing of catalysts to an industrial level while strengthening its leadership in innovative solutions for the chemical industry.

Using X3D technology, catalysts can be manufactured with optimised geometries that combine high mechanical strength and an open structure. This design significantly reduces pressure drop within reactors while increasing the catalytically active surface area. As a result, customers can achieve higher reactor throughput and improved product quality while consuming considerably less energy compared to conventional catalysts.

X3D technology has already been proven in customer applications

BASF has been supplying X3D catalysts to production facilities for both internal and external customers for several years. The technology is highly versatile and can be applied to a wide range of catalyst materials, including precious and base metal catalysts, as well as various support materials. The new production plant in Ludwigshafen will support the broader commercialisation of this technology while helping accelerate development processes and shorten the time to market.

In 2025, Anhui Jintung, a Chinese fine chemical company, deployed BASF’s O4-115 X3D sulphuric acid catalysts at its production facility.

“The plant started up smoothly, and plant performance has significantly improved compared to before. Production achieved a record high, generating substantial economic benefits for our company. We will continue our collaboration with BASF to promote catalyst upgrades and replacements across additional units,” said Eter Zhu, General Manager at An Hui Jintung.

“We are pleased that X3D technology already gives our customers a real competitive edge: We can supply catalysts tailored precisely to their specific chemical processes – quickly and in large quantities. At the same time, we help customers reach their goals, as our catalysts enable them to increase production performance while improving the efficiency of the raw materials they use,” said Detlef Ruff, Senior Vice President Chemical Catalysts and Adsorbents at BASF. “I am truly excited to see these groundbreaking innovations and honored to take on the responsibility for a business that serves as a key enabler of chemical reactions,” said Yaqian Liu, who will succeed Detlef Ruff as of April 1.

Source: BASF