# Refining catalysts: Emissions

Where a catalyst's carbon comes from: dryers and metals

Source page: https://www.materialinsights.org/chemicals/refining_catalysts/emissions/

Where a catalyst's carbon comes from: dryers and metals 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.

Per t of catalyst, cradle-to-gate. Intensity: indicative. Global total: indicative.

#### Share of footprint by lifecycle phase
 Feedstock 40% Production / process 55% Movement 5%

#### Footprint by lifecycle phase

| Phase | Intensity | Share | Main sources of emissions | Notes | Source |
|---|---|---|---|---|---|
| **Feedstock** | not published | 40% | molybdenum, nickel, rare earth and alumina production | Share indicative. | indicative |
| **Production / process** | not published | 55% | gas-fired spray dryers and calciners | Share indicative. | indicative |
| **Movement** | small | 5% | container shipping from US and Europe | Share indicative. | indicative |
| **Use** | outside the cradle-to-gate total | – | coke burned off FCC catalyst in the regenerator | The FCC regenerator is one of a refinery's largest CO2 sources (indicative, often cited as about 20-30% of site CO2). Better catalysts cut coke yield and hydrogen use. | indicative |
| **End of life** | not published | – | spent FCC catalyst to cement kilns or landfill; hydroprocessing catalyst to metal reclaimers | Metal reclamation recovers Mo, Ni, Co and V (USGS MCS 2026, molybdenum). | USGS MCS 2026 |

#### Other environmental impacts

Nickel and vanadium in spent catalyst; dust; rare earth mining impacts in China.

#### Levers to cut emissions

- Catalysts with lower coke selectivity to cut regenerator CO2 (indicative)
- Carbon capture on FCC regenerator flue gas, a large point source
- Spent catalyst metal recovery rather than landfill
- Shift of hydroprocessing towards renewable feeds: Topsoe drew about 20% of 2025 revenue from such fuels

#### India

India's refinery expansions and BS-VI fuel lift hydroprocessing catalyst use; no Indian catalyst LCA found.
 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 |
|---|---|---|---|---|
| **Hydroprocessing of vegetable oils, fats and residues to HVO and SAF** | fuel-level savings, not catalyst-level | not published | Topsoe secured three SAF projects in China in 2025 | Topsoe 2025 results |

 For a climate investor The climate lever is in what the catalyst does, not how it is made: lower-coke FCC catalysts, CO2 capture on regenerators and catalysts for renewable diesel and SAF. Topsoe, Axens, Ketjen and Honeywell UOP sell into SAF projects. The thesis needs SAF mandates and feedstock to hold; refining catalysts for fossil fuels face slow structural decline.

## Other sections

- [Summary](https://www.materialinsights.org/chemicals/refining_catalysts/index.md)
- [Overview](https://www.materialinsights.org/chemicals/refining_catalysts/overview/index.md)
- [Correlation](https://www.materialinsights.org/chemicals/refining_catalysts/correlation/index.md)
- [Production route](https://www.materialinsights.org/chemicals/refining_catalysts/routes/index.md)
- [Production](https://www.materialinsights.org/chemicals/refining_catalysts/production/index.md)
- [Feedstocks](https://www.materialinsights.org/chemicals/refining_catalysts/feedstocks/index.md)
- [Cycles](https://www.materialinsights.org/chemicals/refining_catalysts/cycles/index.md)
- [Trading](https://www.materialinsights.org/chemicals/refining_catalysts/trading/index.md)
- [Movement](https://www.materialinsights.org/chemicals/refining_catalysts/movement/index.md)
- [Regulation](https://www.materialinsights.org/chemicals/refining_catalysts/regulation/index.md)
- [Characteristics](https://www.materialinsights.org/chemicals/refining_catalysts/characteristics/index.md)
- [Relationships](https://www.materialinsights.org/chemicals/refining_catalysts/links/index.md)