FCC Catalyst Market Report 2025

The FCC catalyst market size has grown strongly in recent years. It will grow from $2.89 billion in 2024 to $3.06 billion in 2025 at a compound annual growth rate (CAGR) of 5.8%. The growth in the historic period can be attributed to growth in global refining capacity, global shift towards heavy crude processing, focus on yield improvement, increasing demand for petrochemicals, globalization of refining operations, focus on energy efficiency.

The FCC catalyst market size is expected to see strong growth in the next few years. It will grow to $3.77 billion in 2029 at a compound annual growth rate (CAGR) of 5.4%. The growth in the forecast period can be attributed to increasing complexity in feedstocks, transition to sustainable catalysts, focus on residue upgrading, optimization for propylene production, market penetration in developing regions. Major trends in the forecast period include integration of artificial intelligence, enhanced catalyst regeneration technologies, collaboration for research and development, digitalization and process optimization, adoption of bottom-of-the-barrel technologies.

The increasing demand for petroleum-based products is fueling the growth of fluid catalytic cracking (FCC) catalysts in the coming years. Petroleum products are derived from crude oil and possess similar physical and chemical properties. FCC catalysts enhance the rate of chemical reactions by reducing activation energy during the petroleum refining process. These catalysts are essential for converting high-boiling, high-molecular-weight hydrocarbon fractions from crude oil into valuable products such as olefinic gases, gasoline, and others. For example, in August 2023, the Energy Information Administration, a U.S. government agency, reported that total petroleum consumption in the U.S. averaged approximately 20.28 million barrels per day (b/d) in 2022. This figure included about 1.17 million b/d of biofuels, which comprised 1.002 b/d of fuel ethanol and 0.164 b/d of biodiesel, renewable diesel, and other biofuels combined. This represented a 2% increase from 2021 and a 12% rise from 2020, primarily driven by the U.S. economy's recovery to pre-COVID-19 activity levels. Overall, consumption of nearly all petroleum products in 2022 exceeded levels seen in 2021. Consequently, the growing demand for petroleum-based products is propelling the growth of the FCC catalyst market.

The escalating demand for energy is poised to act as a catalyst for the expansion of the FCC catalyst market in the coming years. Energy demand refers to the requisite quantity of energy needed to fulfill the requirements of specific systems, regions, industries, or societies within a defined period. FCC catalysts play a pivotal role in meeting this demand by facilitating the efficient conversion of heavy hydrocarbons into crucial fuels such as gasoline and diesel. In the United States, for instance, as of April 2023, electricity consumption saw a notable 2.6% increase in 2022 compared to the previous year. This uptick encompassed retail electricity sales to residential and commercial sectors, showcasing a substantial rise, while the industrial sector also experienced a modest increase. Therefore, the mounting energy demand is a significant driver fueling the growth of the FCC catalyst market.

Technological advancements represent a prominent trend gaining ground within the FCC catalyst market. Major players in the fluid catalytic cracking sector are intensively focused on technological innovations to maintain their market standing and are launching cutting-edge technologies to enhance their product portfolios. For example, in March 2022, BASF, a German-based company specializing in fluid catalytic cracking catalysts and systems for refinery applications, introduced Fortitude. This novel FCC catalyst, built upon BASF's multiple framework topologies (MFT) technology, is tailored to optimize the production of butylenes from residue feedstocks while preserving exceptional catalyst activity and superior selectivity.

Major players in the FCC catalyst market are intensifying their focus on introducing cutting-edge catalyst technologies such as PARAGON FCC Catalyst Technology to gain a competitive advantage. This innovative solution, exemplified by W. R. Grace and Co.'s recent launch in October 2023, enhances the efficiency and performance of fluid catalytic cracking processes in the oil and gas industry. The PARAGON technology aids FCC operators in achieving higher fuel yields per unit of CO2 emissions from their FCC units. It offers a range of benefits, including expanding operational parameters, enabling greater flexibility in processing various feedstocks for increased profitability, and optimizing the conversion of feedstocks while maintaining consistent coke yields. Ultimately, this technology enables more sustainable production of fuels, aligning with industry goals for improved environmental impact and enhanced operational efficiency.

In February 2023, Rotating Machinery Services Inc., a U.S.-based firm specializing in engineering, repair, and maintenance services for rotating machinery, acquired the fluid catalyst cracking unit (FCCU) Hot Gas Expander product line from Siemens Energy Inc. for an undisclosed amount. This acquisition brings the intellectual property, inventory, and associated tooling of the FCCU Expander product line into the RMS portfolio. It solidifies RMS's position as the original equipment manufacturer (OEM) service provider for the global installed base of FCCU Hot Gas Expanders. Siemens Energy Inc. is a Germany-based company that supplies hot gas expanders for FCC (Fluid Catalytic Cracking) applications.

Major companies operating in the FCC catalyst market include Axens SA, N.E. Chemcat, Porocel Corporation, Yueyang Sciensun Chemical Co. Ltd., DuPont de Nemours Inc., Magma Ceramics & Catalysts, Albemarle Corporation, W.R. Grace Company, Johnson Matthey, Flour Corporation, Shell plc, Honeywell International Inc., Exxon Mobil Corporation, McDermott International Ltd, Arkema S.A., BASF SE, Sinopec Corporation, China National Petroleum Corporation, Clariant AG, Haldor Topsoe, JGC C&C, Zeolyst International, Versalis, Nanjing Lantian Chemical, Jilin Petrochemical Company, Qingdao Huadong Catalytic Agent Co. Ltd., Fushun Shuntian Petrochemical, Rive Technology, Wuxi Xuelang Chemical Technology, Ecopetrol S.A., Nippon Ketjen Co. Ltd., Sumitomo Chemical Co. Ltd., Universal Oil Products, PetroChina Catalyst Company, Grace Catalysts Technologies.

Asia-Pacific was the largest region in the FCC catalyst market in 2024. The regions covered in the fcc catalyst market report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East, Africa. The countries covered in the fcc catalyst market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, USA, Canada, Italy, Spain.

Fluid catalytic cracking (FCC) is a crucial processing unit in oil refineries designed to enhance gasoline production during the refining process. This chemical process involves breaking down long-chain hydrocarbons into shorter-chain hydrocarbons using heat and a catalyst. The FCC catalyst facilitates a faster chemical reaction, reducing the activation energy required for the petroleum refining process.

The primary products derived from FCC catalyst applications include gasoline sulfur reduction, maximum bottoms conversion, maximum light olefins, maximum middle distillates, and others. Gasoline sulfur reduction focuses on reducing sulfur content, a naturally occurring substance in crude oil unless removed. These catalysts find applications in various processes such as residue, vacuum gas oil, and others, catering to the needs of refineries, environmental considerations, and other end-users.

The FCC catalyst market research report is one of a series of new reports that provides FCC catalyst market statistics, including the FCC catalyst industry global market size, regional shares, competitors with a FCC catalyst market share, detailed FCC catalyst market segments, market trends, and opportunities, and any further data you may need to thrive in the FCC catalyst industry. This FCC catalyst market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenario of the industry.

The fluid catalytic cracking (FCC) catalyst market consists of sales of crystalline zeolite, matrix, filler, and binder. Values in this market are ‘factory gate’ values, that is the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors, and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD, unless otherwise specified).

The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.

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