BASF has launched the new X3D technology, a new additive manufacturing technology for catalysts based on 3D printing. The catalyst produced by this technology has an open structure, which reduces the pressure drop and high surface area of the reactor, which significantly improves the performance of the catalyst. BASF is capable of supplying commercial quantities.
This technology offers greater freedom in catalyst design compared to conventional production techniques. It takes catalyst performance to the next level and helps tailor catalysts to customers’ specific conditions and needs by designing fill patterns, fiber diameters and orientations. Customers benefit from increased reactor throughput, higher product quality and lower energy consumption.
The new catalysts are mechanically stable and have been proven in operation in external commercial plants and in BASF’s practice over several years.
BASF can apply this technology to a variety of existing catalytic materials, including base or noble metal catalysts and support materials. BASF’s sulfuric acid catalysts O4-111 X3D and O4-115 X3D are the first catalysts produced using the new technology and used in industrial plants.