Early-Stage Evaluation of Catalyst Manufacturing Cost and Environmental Impact Using CatCost

The costs and environmental impacts of catalyst manufacture are often neglected during early-stage research because of a lack of accessible, standardized tools to assess them. Here we report the key features of CatCost, a free and public estimation tool for the evaluation of catalyst cost. We demonstrate its functionality with a case study of diverse catalysts (ZSM-5, Pt/TiO₂ and Mo₂C) for the catalytic fast pyrolysis of biomass. We quantified the economic and environmental improvements made by replacing circulating-bed ZSM-5 with more stable, fixed-bed Pt/TiO₂ and Mo₂C catalysts, while revealing the effects of synthesis methods and production scale on catalyst costs. The manufacture of ZSM-5 had a large processing cost contribution that was strongly scale dependent, whereas the costs of the other catalysts were dominated by raw materials at all scales. Furthermore, while ZSM-5 costs the least per kilogram, the more stable catalysts cost half as much per gallon of fuel. [Figure not available: see fulltext.].