With the new X3D technology, sulphuric acid catalysts manufacturer BASF expands its experience in catalyst production into additive manufacturing. Based on 3D printing, catalysts produced with X3D technology combine proven active materials with a new shaping technology. The result is a high reactivity, a higher freedom of catalyst design and a lower pressure drop minimising energy consumption.

Key Facts

• Proven-track record in industrial plants since 2019
• BASF's sulfonation plant in Italy
• Versatile technology that can be applied to a wide range of catalytic materials
• Possibility to customise catalysts to customers’ specific conditions and needs

Unlock Cost Savings and Sustainability with BASF’s Sulphuric Acid: O4-115 X3D

X3D is a breakthrough shaping technology which will help you cut down costs and boost your sustainability goals. Since 2019, BASF has been selling Sulphuric Acid catalyst O4-115 based on the X3D technology. These new 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 €/y
• Caustic soda saving: 162.4 t/y, or 58 000 €/y
• Energy savings owing to decreased pressure drop: 106 MW/y, or 18 000 €/y
• Total savings: €100 000/y

Why BASF?

BASF is one of the leading manufacturers of sulphuric acid catalysts worldwide, leveraging its own sulphuric acid production expertise. The company operates four sulphuric acid plants at its headquarters in Ludwigshafen, in Germany, where the latest catalyst technologies are used.

For the new development of catalysts, in-house sulphuric acid production is a huge advantage because BASF can gain important insights on the performance and long-term stability of the catalysts, and its customers can directly benefit from these findings. In addition, it is continuously investing in sulfuric acid catalyst research to help its customers be even more successful.

When customers work with BASF, they benefit from our decades of experience in:

• Conversion evaluation
• Performance optimisation
• Technical assistance
• Customer sample analysis
• On-site plant support
• Spent catalyst disposal assistance
• Process performance evaluation

Contact our experts in Africa: Dr. Saul Colley, Catalysts and Absorbents Expert Send your enquiry here