Autocatalysts: Emissions
Why recycled metal cuts the catalyst footprint by 98%
What this tab covers The greenhouse-gas footprint per tonne, split by lifecycle phase (feedstock, production, movement, use, end of life), the global total, other environmental impacts, levers and low-carbon routes, India's position, and where the investment opportunity lies. Emission intensity 0.12 t CO2e per vehicle set range about 0.05-0.25 · 4 g PGM in the 2025 automotive mix (68% Pd, 25% Pt, 7% Rh) at IPA intensities is about 124 kg CO2e if all primary, about 90 kg with 30% recycled metal, plus about 10-30 kg for substrate and washcoat (indicative) Global emissions per year 8.50 Mt CO2e per year 2025 · 95 t Pt x 36,828 + 256 t Pd x 28,094 + 28 t Rh x 38,027 = about 11.7 Mt if all primary, reduced to about 8-9 Mt for about 30% recycled supply (indicative)Per catalyst system for one light vehicle (about 4 g PGM, indicative), cradle-to-gate. Intensity: IPA Life Cycle Assessment of PGMs, 2022 production year (Apr 2025), via PGM tiles; indicative. Global total: IPA 2025; JM 2026; WPIC 2026; indicative.
Share of footprint by lifecycle phase
Feedstock 85% Production / process 12% Movement 3%Footprint by lifecycle phase
| Phase | Intensity | Share | Main sources of emissions | Notes | Source |
|---|---|---|---|---|---|
| Feedstock | about 0.09-0.12 t CO2e per vehicle set (indicative) | 85% | deep PGM mining and smelting on South Africa's coal-heavy grid | Recycled PGMs cut this by about 98%. | IPA 2025 via PGM tiles |
| Production / process | about 0.01-0.03 t (indicative) | 12% | cordierite firing, washcoat calcination | Share indicative. | indicative |
| Movement | small | 3% | air freight of metal, road and sea for bricks | Share indicative. | indicative |
| Use | outside the total; net benefit | – | catalyst converts CO, HC and NOx; slight fuel penalty from back-pressure; some N2O and NH3 slip | Catalysts avoid large air-pollution harms but do not cut tailpipe CO2. | indicative |
| End of life | recycling about 0.5 t CO2e per t of metal recovered | – | smelting of spent converters | Recycled metal emits about 477-497 t CO2e per t versus 28,000-38,000 t primary (IPA). | IPA 2025 via PGM tiles |
Other environmental impacts
PGM mining causes SO2 emissions (Norilsk) and large water and tailings footprints; catalysts greatly reduce urban NOx, CO and particulates.
Levers to cut emissions
- Higher recycling rates of spent converters (recycled rhodium about 29% of 2025 demand)
- Thrifting: fewer grams per vehicle
- Platinum for palladium substitution (lower-carbon metal per gram is similar; mainly a price lever)
- Renewable power at South African mines and smelters
- Electrification removes the need entirely
India
India's vehicle catalysts rely entirely on imported PGMs; formal scrappage since 2021 is starting a domestic converter recycling stream, but no large PGM refinery has been verified.
Emission figures are indicative global averages from the life-cycle studies named; actual footprints vary widely by site, energy mix and method.Low-carbon routes
| Route | Intensity | Cost premium | Status | Source |
|---|---|---|---|---|
| Catalysts made with recycled PGMs | about 98-99% lower metal footprint (IPA) | none; recycled metal is fungible | Umicore, JM, BASF and Heraeus run large recycling refineries; JM new UK refinery due 2027 | IPA 2025; JM FY2025/26 results |