Refinery Catalyst Market

Refinery Catalyst Market Growth and Industry Forecast

The refinery catalyst market is valued at USD 12.0 billion in 2025 and is projected to reach USD 16.1 billion by 2032, growing at a CAGR of 4.3%.

Refinery Catalyst Market Summary: Key Insights & Trends

• Fluid Catalytic Cracking (FCC) dominates the market with around 40% share, driven by its central role in converting heavy feedstocks to high-value fuels.
• Zeolite-based catalysts lead with over 32% market share, supported by their extensive use in FCC and hydrocracking applications.
• Asia Pacific accounts for ~36% of global refinery catalyst consumption, led by rapid capacity expansion in China and India.
• Hydrocracking catalysts emerge as the fastest-growing segment, propelled by refinery upgrades and heavier crude processing.
• North America holds ~20% share, sustained by stringent Tier 3 fuel regulations and consistent catalyst replacement cycles.
• Europe’s demand is shaped by emission compliance and biofuel transition, with growth in renewable feedstock processing catalysts.

Key Growth Drivers

• Tight Emission Norms Drive Adoption of Advanced Refinery Catalysts for Cleaner Fuels

Growing global pressure to meet stringent fuel quality and emission standards such as Euro 6 and Tier 3 has accelerated the adoption of advanced hydrotreating and hydrodesulfurization catalysts. Refiners are increasingly relying on aluminium-cobalt-molybdenum and nickel-molybdenum catalysts, which enhance sulfur and nitrogen removal efficiency in diesel and gasoline production.

According to studies published in MDPI, catalysts based on Co-Mo-S nanoclusters exhibit superior hydrogenolysis activity, enabling the production of ultra-low sulfur fuels below 10 ppm while improving hydrogen utilisation and catalyst life. As global fuel demand continues to rise, particularly in Asia and the Middle East, the Refinery Catalyst Market is expanding as refineries upgrade units to meet emission compliance, driving demand for high-performance catalysts that support cleaner and more efficient fuel processing.

• Global Refinery Upgrades and Capacity Growth Spur Demand for High-Performance Catalysts

Rising investments in refinery modernisation and capacity expansion are accelerating demand in the Refinery Catalyst Market as facilities adapt to process heavier, more complex crude grades and produce cleaner fuels. Refineries with a high Nelson Complexity Index (NCI) typically above 10 require advanced catalysts to optimize cracking, hydroprocessing, and reforming operations for higher yields of light and middle distillates.

According to the International Energy Agency (IEA), global refining capacity is projected to expand by about 3.3 million barrels per day by 2030, led by new and upgraded complexes in Asia and the Middle East, where integrated petrochemical-refining models are being adopted.

These upgrades drive the use of noble metal and transition metal catalysts that enhance energy efficiency and extend operational lifespans, aligning with the shift toward higher-value, low-sulfur products in an evolving fuel landscape.

Key Restraints

• Global Energy Transition Toward Biofuels Reduces Conventional Refinery Catalyst Demand

The global push toward biofuels and renewable transport energy is gradually reducing reliance on conventional crude refining, which in turn may limit demand in the Refinery Catalyst Market. As liquid biofuels and renewable hydrogen gain momentum, investment in traditional hydrocracking and heavy-oil upgrading processes may slow.

While exact figures vary, refiners may defer catalyst reloads or shorten investment horizons in certain units. At the same time, many current catalysts (e.g., cobalt-molybdenum for hydrodesulfurization) require redevelopment to handle oxygenated feedstocks   increasing technology risk and capital cost..

• Geopolitical Instability and Raw Material Fluctuations Strain Catalyst Supply Chains

Geopolitical tensions and constrained supply of critical raw materials such as molybdenum are increasing production costs and delaying catalyst deliveries in the Refinery Catalyst Market.

According to the U.S. Geological Survey, U.S. mine production of molybdenum concentrate fell by 3 % in 2024 compared with 2023, highlighting supply pressure. These disruptions raise entry barriers for smaller catalyst producers and force refiners to factor higher costs and longer lead times into their planning. The ripple effect is slower catalyst reload cycles and heightened risk of capacity constraints in key refining processes.

Refinery Catalyst Market Trends and Opportunities

• Expanding Hydrocracking Projects in Emerging Regions Fuel Demand for Advanced Catalysts

Growth of new hydrocracking and residue-upgrading projects in the Middle East and Africa is creating significant demand in the Market, as refiners adopt advanced catalysts to maximise conversion and meet low-sulfur fuel requirements. Key projects such as Kuwait’s Mina Abdullah Clean Fuels Project showcase the expansion of hydrocracking capacity and corresponding catalyst reload cycles.

As refineries shift toward heavier and more sulphur-rich feedstocks, demand rises for nickel-, cobalt- and mixed-metal hydrocracking catalysts that deliver high diesel yields and extended operating life. The development of integrated petrochemical-refining complexes further enhances opportunities for catalyst suppliers with high-performance solutions suited for complex conversions.

• Rising Zeolite and Molybdenum Use Enhances Refinery Efficiency and Catalyst Performance

Zeolites remain the backbone of the Market, accounting for the majority of global fluid catalytic cracking (FCC) catalyst consumption due to their exceptional cracking selectivity and thermal stability.

Their critical role in converting heavy hydrocarbons into lighter, high-value fuels makes them indispensable for refinery efficiency. Molybdenum-based catalysts are gaining traction in hydrotreating and hydrodesulfurization units for their high sulfur-removal efficiency and stability under severe operating conditions, supporting compliance with Euro 5 and Euro 6 fuel standards. Asia Pacific, contributing approximately 60-65% of global zeolite output, strengthens the supply base and export potential, particularly for advanced formulations used in FCC and alkylation processes aimed at producing high-octane gasoline blends.

Segment-wise Trends & Analysis

• Fluid Catalytic Cracking Leads While Hydrocracking Becomes Fastest-Growing Refinery Segment

The Fluid Catalytic Cracking (FCC) segment retains the largest share, around 40%  of the Market in 2025, because FCC units remain the primary conversion technology for upgrading vacuum gas oils and residues into gasoline, LPG, and light olefins. More than 95% of global zeolite consumption in refining is attributed to FCC catalysts, underscoring its centrality in refinery operations.

Recent innovations such as BASF’s Fourtiva™ and Altrium™ FCC catalysts demonstrate the market’s emphasis on higher butylene yield, improved naphtha octane, deeper bottoms conversion, and reduced coke formation. This technology-driven differentiation strengthens the competitive position of integrated refiners and catalyst suppliers who deploy advanced matrix-zeolite architectures.

FCC dominance is further reinforced by refinery upgrading programs across the U.S., Middle East, China, and India, where refiners seek higher-value products and better feedstock flexibility.

• Zeolite Catalysts Dominate as Molybdenum Gains Momentum in Desulfurization Applications

Zeolite catalysts maintain dominance in the Market with over 32% share in 2025, driven by their extensive use in fluid catalytic cracking (FCC) and hydrocracking processes. Their crystalline aluminosilicate framework provides tunable acidity and shape selectivity essential for maximizing gasoline, propylene, and aromatics yields.

Continuous product innovation reinforces this leadership   BASF’s ZEAL™ FCC additive exemplifies how high-activity zeolitic materials are optimised for propylene production and improved olefin selectivity. The segment’s strength is further supported by the integration of advanced zeolite manufacturing platforms, such as Zeolyst International’s Opal Infinity™ portfolio for circular and sustainable applications, positioning zeolites as the cornerstone of catalytic reforming and emerging petrochemical pathways.

Molybdenum-based catalysts are witnessing accelerated adoption in hydrotreating and hydrodesulfurization (HDS) units due to their superior sulfide-phase stability and hydrogenation activity. Supported on alumina and often combined with nickel or cobalt, these catalysts effectively remove refractory sulfur compounds to meet ultra-low-sulfur fuel mandates.

Regional Trends & Analysis

Technological Advancements and Regulatory Policies Sustain North American Refinery Catalyst Demand

North America remains a mature yet strategically significant region in the Refinery Catalyst Market, underpinned by strong technological innovation and stringent environmental regulations. The United States, with about 132 operable petroleum refineries as of 2024, continues to drive steady catalyst demand through sustained secondary processing activity. The region’s refining infrastructure remains heavily focused on producing ultra-low sulfur fuels, which sustains the consumption of advanced hydrotreating and hydrocracking catalysts.

North America is estimated to account for around 20% of global refinery catalyst consumption in 2025, reflecting consistent replacement cycles and modernization of catalytic units. Refiners across the region are adopting high-performance catalyst formulations such as Co-Mo, Ni-Mo, and advanced zeolites to enhance operational efficiency, meet ultra-low sulfur diesel and gasoline standards, and extend catalyst life.

U.S. Refinery Catalyst Market - 2025 Snapshot & Outlook

The U.S. Refinery Catalyst Market shows stable demand driven by regulatory compliance and efficiency upgrades. Tier 3 gasoline and renewable fuel standards sustain catalyst replacement cycles, while shale oil output boosts the need for catalysts suited to lighter crudes. Expanding petrochemical and renewable fuel sectors further drive adoption of advanced FCC and hydrotreating catalysts for olefin and bio-feedstock processing.

Asia Pacific Leads Global Refinery Catalyst Market with Expanding Refining Capacity

Asia Pacific is the largest regional consumer of refinery catalysts in 2025, driven by rapid refinery capacity expansion, integrated refinery-petrochemical projects, and rising domestic fuel and petrochemical demand across China, India and Southeast Asia.

New and upgraded high-complexity refineries in the region increase reload cycles for FCC, hydrocracking and hydrotreating catalysts, while feedstock variability (heavier and mixed crudes) raises demand for robust, selective formulations. Given the scale of capacity additions and retrofit activity reported for Asia, an estimated ~36% of global catalyst consumption in 2025 is reasonably attributable to the Asia Pacific.

China Refinery Catalyst Market - 2025 Snapshot & Outlook

China combines large refining throughput with strong local catalyst manufacturing capability. Its rapid capacity growth over the past decade and the integration of petrochemical units into refineries have elevated demand for FCC additives, hydrocracking and hydrotreating catalysts to meet stricter fuel standards.

China’s extensive refining and petrochemical integration also supports domestic zeolite and catalyst production, strengthening its role as both a major consumer and supplier in the global market. China likely represents a substantial portion of the Asia Pacific’s consumption.

India Refinery Catalyst Market - 2025 Snapshot & Outlook

India is one of the fastest-growing major markets for refinery catalysts, supported by steady capacity additions, rising domestic fuel demand, and upgrades to meet Bharat Stage VI emission standards. Large expansion projects and downstream petrochemical integration increase requirements for hydrotreating and hydrocracking catalysts.

India’s growth trajectory and project pipeline make it an increasingly important regional demand centre for both conventional and speciality catalyst formulations.

European Refinery Catalyst Market Driven by Energy Transition and Regulatory Compliance

Europe faces a complex market environment characterised by stringent environmental regulations, energy transition policies, and geopolitical challenges affecting refining operations. The region's refinery catalyst demand reflects both regulatory compliance requirements and the strategic shift toward sustainable fuel production. Recent geopolitical developments, particularly the Russia-Ukraine conflict, have significantly impacted crude oil supply patterns and refinery utilisation rates across European markets.

Germany Refinery Catalyst Market - 2025 Snapshot & Outlook

Germany’s refinery catalyst market remains resilient amid the energy transition, driven by Euro 6 emission standards, renewable fuel integration, and petrochemical expansion. Demand is supported by upgrades for cleaner fuel production and premium-grade outputs, while investments in sustainable aviation fuel and refinery-chemical integration sustain catalyst consumption across applications.

France Refinery Catalyst Market - 2025 Snapshot & Outlook

France’s refinery catalyst market is shaped by sustainability goals and biofuel mandates, driving demand for hydrotreating catalysts used in renewable fuel production. Hydrogen integration supports advanced refining processes, while export-oriented refineries sustain catalyst use for international-grade fuels. Emerging carbon capture initiatives further create opportunities for CO₂ conversion catalysts.

Competitive Landscape Analysis

The global refinery catalyst market is moderately consolidated, with competition concentrated among a few multinational companies that dominate technological innovation and global supply chains.

Leading players such as BASF SE, W.R. Grace & Co., Albemarle Corporation, Johnson Matthey Plc, and Haldor Topsoe A/S collectively hold a significant market share, driven by strong portfolios in hydrotreating, hydrocracking, and FCC catalysts.

These companies leverage long-term partnerships with refiners, proprietary catalyst formulations, and integrated R&D capabilities to maintain a competitive advantage. The market exhibits oligopolistic characteristics, where continuous innovation and regulatory alignment define competitive positioning.

Key Companies

• Albemarle Corporation
• Haldor Topsoe A/S
• Chevron Lummus Global
• Grace & Co.-Conn
• BASF
• Johnson Matthey Plc.
• Axen
• Honeywell International Inc.
• Advanced Refining Technologies LLC (ART)
• Sinopec Corporation
• Shell plc.

Recent Developments:

• In 2025, Albemarle Corporation announced the sale of a 51% stake in Ketjen Corporation’s refining catalyst solutions business to KPS Capital Partners and its 50% stake in the Eurecat joint venture to Axens SA. The transactions, expected to close in the first half of 2026, will generate approximately $660 million in pre-tax proceeds. This move reflects Albemarle’s strategy to streamline its portfolio and focus on core operations while reshaping its position in the global refinery catalyst market.
• In September 2025, Clariant partnered with SYPOX to supply catalysts for the world’s largest electric steam methane reformer (e-SMR), a 10 MW unit designed to produce around 150 tons of syngas daily with minimal CO₂ emissions. This collaboration highlights Clariant’s role in advancing electrified reforming technologies that support refinery decarbonization and hydrogen production. The development reinforces the shift toward sustainable and low-emission catalyst solutions within the global refinery catalyst market.

Global Refinery Catalyst Market Segmentation-

By Refinery Unit             

• Fluid Catalytic Cracking (FCC)
• Hydrocracking
• Catalytic Reforming
• Alkylation
• H-Oil & Residue Upgrading Units
• Hydrotreating
• Naphtha Hydrotreating
• Distillate Hydrotreating

By Catalyst Type        

• Zeolites
• Molybdenum-based Catalysts
• Cobalt-based Catalysts
• Nickel-based Catalysts
• Platinum Group Metal (PGM) Catalysts
• Others

By Region

• North America
• Europe
• Asia Pacific
• Latin America
• Middle East & Africa