Recent innovations in catalyst technology by leading chemical catalyst companies

Here are some recent innovations in catalyst technology by leading chemical catalyst companies:

BASF
- X3D® Technology: BASF has developed a groundbreaking additive manufacturing technology for catalysts based on 3D printing. This technology produces catalysts with optimal shapes to maximize performance and efficiency while minimizing energy consumption. The catalysts are mechanically robust and feature an open structure, significantly reducing pressure drop across reactors and increasing surface area. This leads to improved catalyst performance, helping customers achieve greater efficiency in their plants, higher product quality, and lower energy consumption. The versatility of X3D technology allows BASF to customize catalysts according to specific customer requirements. BASF is investing in additional production capacity for this technology, with a new plant expected to be operational in 2026.
- Fourtiva™ Fluidized Catalytic Cracking Catalyst: In 2024, BASF introduced Fourtiva™, a new Fluid Catalytic Cracking (FCC) catalyst for gasoil to mild resid feedstock. It incorporates BASF’s newest Advanced Innovative Matrix (AIM) and the Multiple Frameworks Topology (MFT) technologies to maximize butylene yields and selectivity over propylene while improving naphtha octane, LPG olefinicity, and minimizing coke and dry gas.

Johnson Matthey
- Alchemite™ Machine Learning Software: Johnson Matthey has successfully applied the Alchemite™ machine learning software to the development of catalysts for clean air and life science applications. This software has enabled the identification of improved formulations and the potential to double experimental efficiency in clean air applications. In life science technologies, it delivered a 4% yield improvement in a key process and identified a 5 times speedup for another experiment.
- Catalyst-Coated Membrane Production Facility: In 2023, Johnson Matthey signed an investment agreement with the Jiading District in Shanghai to build a new catalyst-coated membrane production facility. This facility will provide production capability for multiple PEM fuel cell applications and PEM electrolysers, which turn water into hydrogen and oxygen. The catalyst-coated membranes consist of platinum cathodes and iridium anodes, maximizing hydrogen production.

Clariant
- MegaMax® Catalyst: Clariant’s MegaMax® catalyst was chosen by European Energy for the world’s largest e-methanol plant located in Kasso, Denmark.
- CLARITY™ Service Portal: Clariant launched CLARITY™, a service portal that provides customers with 24/7 access to their real-time catalyst performance data, as well as advanced visualization, analysis, and monitoring tools.
- New CATOFIN Catalyst Production Site: In 2023, Clariant inaugurated its new CATOFIN catalyst production site in Jiaxing, Zhejiang Province, China, intensifying its production capacity and expanding its footprint in China.
- Partnership with Conser: Clariant strengthened its presence in the maleic anhydride industry by forging a partnership with Conser, part of the MAIRE Group, to develop and supply next-generation catalysts for producing maleic anhydride.

UOP (Honeywell)
- Breakthrough Catalyst Technology for Hydrogen Production: In October 2023, UOP unveiled a breakthrough catalyst technology for the production of hydrogen from natural gas, paving the way for cleaner fuel options.

UNICAT Catalyst Technologies, LLC
- Magcat® Textured Sphere Reformer Catalysts: UNICAT commercialized Magcat® Textured Sphere reformer catalysts, which offer key advantages such as strength, greater geometric surface area, heat transfer, and low pressure drop.
- Advanced Filtration System (AFS) Technology: UNICAT introduced transformative innovation to its AFS technology, significantly improving the protection of hydrotreaters and delivering step-change uptime benefits. The next generation of AFS has optimized uniform flow channels, maximizing foulant capture and increasing unit cycle times by at least 50%.

These innovations demonstrate the continuous efforts of leading chemical catalyst companies to enhance catalyst performance, efficiency, and sustainability, driving advancements in various industries.