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Do EVs Really Use More Rare Earths Than Petrol Cars?

Published on 7th December 2025 by Simon Fearby

Is an EV A Good Idea For Me Post Thumbnail

How Rare Earths Power Petrol: From Mines to Your Fuel Tank

I was on a road trip with 2 elderly people (who were a bit sceptical about EV's). As we were driving past a huge open cut coal mine the topic inevitably turned to the impacts of mining. One passenger said that "I was all for electric vehicles but they are so damaging to the environment".

This post is the result of my research into the mining, usage and recycling of rare earth minerals

What are Rare Earths

The rare earth elements (the 15 lanthanides plus scandium and yttrium) aren’t actually rare - they’re just hard to separate. Cerium is the most abundant at about 66 ppm, followed by lanthanum (39 ppm), neodymium (38 ppm), and yttrium (33 ppm). Praseodymium sits at 9.2 ppm, samarium 7.1 ppm, gadolinium 6.2 ppm, dysprosium 5.2 ppm, and erbium 3.5 ppm. Europium comes in at 2.1 ppm, ytterbium 3.0 ppm, holmium 1.3 ppm, terbium 1.2 ppm, and thulium is much rarer at 0.52 ppm. Lutetium is the scarcest lanthanide at 0.31 ppm. Scandium, while technically not a lanthanide, is geochemically associated and sits at roughly 22 ppm, making it more abundant than many. For comparison, tin is ~2 ppm and silver is ~0.08 ppm - so the “rare” label is more about extraction difficulty than actual scarcity in Earth's crust.

Rare Earth Element Symbol
ScandiumSc
YttriumY
LanthanumLa
CeriumCe
PraseodymiumPr
NeodymiumNd
PromethiumPm
SamariumSm
EuropiumEu
GadoliniumGd
TerbiumTb
DysprosiumDy
HolmiumHo
ErbiumEr
ThuliumTm
YtterbiumYb
LutetiumLu

Rare Earth usage in Petroleum refining

Petrol is not a “rare-earth-free” product. In fact, the petrol industry is one of the largest consumers of lanthanum and cerium on the planet.

Every litre of petrol relies on synthetic zeolite catalysts enhanced with rare earths. These catalysts are manufactured in chemical plants - not mined. Rare earths (mainly lanthanum and cerium) come from operations in China, Australia, the United States and elsewhere.

To turn crude oil into usable petrol, refineries depend on:

Every litre of petrol uses rare earths during production. Later, most petrol cars use rare and precious metals again inside their catalytic converters. Petrol is one of the biggest, quietest consumers of rare earths globally.

Rare Earth Mining: Lanthanum and Cerium

The story starts at rare earth mines extracting:

These are typically found in bastnäsite and monazite ores, mined in:

Lanthanum and cerium together account for 60–70% of global rare earth oxide output. A major reason is their heavy use in refinery catalysts.

Refining and Separating the Rare Earths

After mining, the ore undergoes:

These refined oxides meet the purity required for petrochemical catalysts, magnets, electronics and other high-tech applications.

Catalyst Manufacturers: Turning Rare Earths into Zeolite Catalysts

The refined lanthanum and cerium oxides are purchased by catalyst manufacturers such as:

These companies create synthetic zeolite crystals for oil refining - primarily Zeolite Y and its high-performance variants (USY, REY, REUSY).

Synthetic Zeolites (Not Mined Minerals)

Refinery-grade zeolite is grown in hydrothermal chemical reactors using:

These engineered zeolites provide:

Natural zeolites are too inconsistent and thermally unstable for petroleum cracking, so they are never used in modern FCC units.

Ion Exchange with Rare Earth Metals

Once the crystal is formed, it undergoes rare-earth ion exchange:

The zeolite is then blended with clays and binders and spray-dried into tiny catalyst spheres (typically 50–150 µm). These become the FCC catalyst used in refineries.

Inside the Refinery: Fluid Catalytic Cracking (FCC)

FCC units crack heavy gas oils into petrol, diesel and lighter hydrocarbons. Typical conditions:

The rare-earth-enhanced catalyst enables:

Without lanthanum and cerium, refineries face:

Spent Catalyst and Waste

FCC catalyst slowly degrades and is continuously removed and replaced. Spent catalyst contains:

Nickel, Molybdenum, and Cobalt in Diesel Refining

Diesel production relies heavily on hydrotreating and hydrocracking, two refinery processes that remove sulphur, nitrogen, and other contaminants while upgrading heavier fractions into clean-burning diesel fuel. These processes use catalysts made from nickel (Ni), molybdenum (Mo), and in some cases cobalt (Co) supported on alumina.

Why these metals matter

How much of each metal is used?

Catalyst compositions vary by refinery, but typical metal loadings (by weight of catalyst) are:

Catalyst Type Metal Loading (Typical) Where It's Used
NiMo (Nickel–Molybdenum) Nickel: 2–5%
Molybdenum: 10–20%
Hydrotreating and hydrocracking units for diesel and jet fuel.
CoMo (Cobalt–Molybdenum) Cobalt: 1–4%
Molybdenum: 10–20%
Hydrotreating for sulfur removal (ULSD and marine fuels).

A medium-to-large refinery may carry **hundreds of tonnes of hydrotreating catalyst** in circulation. Metal content per unit: typically **10–40 tonnes of Mo**, **2–10 tonnes of Ni**, and **1–5 tonnes of Co**, depending on configuration and throughput.

How long do these catalysts last?

Hydrotreating catalysts usually last:

Over time, catalysts become deactivated due to:

Recycling of Nickel, Molybdenum, and Cobalt

Unlike FCC catalysts—which are often discarded because of low-value REE recovery—hydrotreating catalysts are highly recyclable because Ni, Mo, and Co have significant market value.

Metal Recycling Rate How It’s Recovered What Happens After
Nickel 80–95% Recovered from spent catalyst through roasting, leaching, and solvent extraction. Often reused in stainless steel, alloys, or new catalyst production.
Molybdenum 85–95% Recovered as molybdenum oxide via thermal or chemical extraction. Converted into molybdenum metal or catalysts; extremely high reclamation value.
Cobalt 70–95% Recovered through hydrometallurgical refinement. Used in alloys, batteries, or new catalyst material.

Are these metals “lost” in the refining process?

No. Unlike REE-based FCC catalysts (lanthanum/cerium), which often end up as landfill waste or low-grade filler, nickel, molybdenum, and cobalt catalysts are:

The recycling rate is high because:

In practice, most hydrotreating catalysts achieve 70–95% total metal recovery, depending on contamination levels and the recycler’s technology.

Octane Production and Why Catalysts Matter

The FCC unit produces most of the high-octane molecules that modern engines require:

Rare-earth-enhanced catalysts directly influence how much of this valuable high-octane fraction a refinery can produce.

Petrol Catalytic Converters: Rare Metals in the Car Itself

Once petrol is produced, more rare and precious metals appear again in the exhaust system. Catalytic converters contain:

These metals convert toxic exhaust gases into less harmful ones - a second major point where rare metals enter the petrol supply chain.

The Big Picture: Petrol Depends on Rare Earths

Petrol is not a simple, mineral-free product. It depends heavily on rare earths at multiple stages:

Without rare-earth-enhanced catalysts, the modern petrol supply chain would produce far less fuel, at lower octane, higher cost and higher emissions.

Rare Earths in Petrol vs. EVs - The Fast, Fair Comparison

Petrol isn’t made at modern scale without rare earths. Refineries depend on synthetic zeolite catalysts boosted with lanthanum and cerium to crack crude into high-octane fuel efficiently. Remove those rare earths and output drops, octane falls, emissions rise, and costs jump. Most drivers never see this, but every litre of petrol relies on rare-earth mining long before it reaches a service station.

Refinery catalysts slowly wear out and are discarded, meaning the average petrol driver indirectly “consumes” around 8–12 grams of rare-earth oxides per year just through fuel production. None of this is recycled. It’s a continuous upstream material cost baked into every kilometre driven.

Then there’s the catalytic converter. Nearly all petrol cars contain 5–15 grams of cerium oxide and 1–3 grams of lanthanum oxide to stabilise the catalyst and store oxygen. These are almost never recovered when the vehicle is scrapped; they end up in landfill or smelter waste. So petrol cars rely on ongoing rare-earth extraction and generate rare-earth waste - it’s just invisible to the owner.

And that’s only part of the upstream chain. The petroleum system requires enormous recurring inputs: drilling rigs use high-strength alloys and rare-earth permanent-magnet motors; offshore platforms rely on pumps, sensors, and navigation gear containing neodymium and praseodymium; tankers burn vast amounts of bunker fuel and use rare-earth-based winches and compressors; and the global network of pipelines, trucks, and refineries consumes steel, chemicals, electricity, and diesel every single year.

EVs absolutely have their own material footprint, especially in motors and batteries. But the idea that petrol cars are “rare-earth free” simply isn’t true. Petrol uses rare earths continuously and upstream, while EVs use most of theirs once - and those can be recycled. If someone wants a fair debate, the whole lifecycle needs to be compared, not just the battery.

Rare-Earth Recovery: Petrol Refining vs. Lithium-Ion Batteries

Petroleum refining is one of the world’s biggest hidden consumers of rare earths - particularly lanthanum and cerium. These oxides are embedded in the porous structure of cracking catalysts and slowly poison, sinter, and wear out during use. When a catalyst batch is spent, refineries dump or landfill it. Globally, this creates hundreds of thousands of tonnes of waste every year containing 1–5% rare-earth oxides. Recovery is technically possible but almost never done: the rare earths are dispersed at low concentration, chemically “locked” inside contaminated catalyst dust, and mixed with nickel, vanadium, sulfur, and coke. The cost of extraction exceeds the value of the recovered material, so the industry simply treats it as disposable consumable waste.

Petrol engines also carry rare earths in their catalytic converters - typically 5–15 grams of cerium oxide and 1–3 grams of lanthanum oxide. These additives store oxygen and stabilise the platinum-group metals. Unlike the platinum, palladium, and rhodium (which are worth hundreds of dollars per converter), the lanthanum and cerium are not recovered because their value is too low relative to the complexity of separating them. When a converter is recycled, the rare earths mostly end up locked in slag from smelting or discarded entirely. The result: almost 100% of rare-earths used in the petroleum cycle are permanently lost.

In contrast, lithium-ion batteries are far easier to reclaim rare earths from - when they contain them at all. Nickel-manganese-cobalt (NMC) and nickel-cobalt-aluminium (NCA) chemistries contain no rare earths; their value lies in cobalt, nickel, copper, and lithium. Even the motors that use neodymium magnets place the rare earths in large, solid, mechanically recoverable chunks. When an EV battery or motor reaches end-of-life, the metals are concentrated, not dispersed. Black-mass recycling processes - hydrometallurgical leaching, reductive acid extraction, and solvent separation - routinely achieve 90–95% recovery of key materials. Neodymium-iron-boron magnets can be directly reprocessed using sintering or hydrogen decrepitation with very high yield. Unlike petroleum catalysts, these materials are physically accessible and economically worth recovering.

The fundamental difference is simple: petroleum rare earths are consumed and lost as part of a disposable industrial process, while EV rare earths sit in discrete, high-value components designed to be recycled. One system permanently throws rare earths away; the other retains them in concentrated form for decades and can reclaim them efficiently at end-of-life. This is why the long-term rare-earth demand curve for EVs trends downward with recycling, while the petroleum sector’s demand remains permanently tied to constant mining.

What if petroleum rare earth mining stopped overnight?

Hypothetically, if all rare earth elements (REEs) used in fluid catalytic cracking (FCC) – mainly lanthanum and cerium – stopped being mined and sold, global fuel supplies would not fail evenly.

Refineries burn through FCC catalyst constantly. Without fresh REE-based catalyst, FCC units would lose activity over a few months and petrol and jet-fuel production would fall off a cliff. Diesel, bunker fuel and shipping would hold up longer, but they would still be dragged into a price and supply shock as the whole refining system chokes.

In short: take away REE catalysts and you don’t just “slightly” inconvenience petrol – you cripple the high-value, high-octane and aviation parts of the system first, while diesel and shipping stagger on under higher costs.

Who controls the key minerals behind refinery catalysts?

The table below shows the main mining and refining powerhouses for the minerals that matter most to FCC and hydrotreating catalysts: light rare earths (lanthanum, cerium), nickel and cobalt. It’s deliberately simplified for readability – the point is the concentration of supply, not an exhaustive country list.

Leading countries for mining and refining key refinery minerals (high-level)
Mineral Role in petroleum Leading mining countries Leading refining / processing countries Notes
Rare earth elements
(lanthanum, cerium)
Core to FCC catalysts used to crack heavy oil into petrol and jet fuel with high activity, selectivity and stability. China (dominant),
United States,
Myanmar,
Australia,
Thailand,
Vietnam
China (overwhelming majority of separation/refining),
plus smaller capacity in:
Malaysia (Lynas),
Australia,
United States,
Estonia and others
China controls most REE refining capacity globally, including the light REEs used in FCC catalysts. If China’s refined output stopped, FCC catalyst supply would be crippled even if some ore were mined elsewhere.
Nickel Used in hydrotreating and hydrocracking catalysts to remove sulphur and upgrade fuels; also critical for stainless steels and some battery chemistries. Indonesia (by far #1),
Philippines,
Russia,
Canada,
China,
New Caledonia,
Australia,
Brazil
Indonesia and China together produce the bulk of refined nickel, with additional refining in Russia, Canada, Japan and others. Indonesia has exploded as a nickel mining and processing hub, heavily financed and integrated with Chinese refining and stainless/battery demand. Refined nickel production is highly concentrated in just a few countries.
Cobalt Used in some refinery hydrotreating catalysts and metal alloys; more famous now for its role in many lithium-ion battery chemistries. Democratic Republic of Congo (DRC) (by far #1),
Indonesia,
Russia,
Australia,
Philippines,
Madagascar, Cuba and others
China (dominant refined cobalt producer),
plus Finland,
Canada,
Belgium,
Norway and others
DRC supplies the majority of mined cobalt, but most of it is shipped out as intermediates and refined in China. A handful of European and Canadian plants provide smaller but strategically important refined output.

The common thread: mining is concentrated, but refining is even more concentrated, with China and a short list of partners controlling most of the choke points that keep FCC and hydrotreating catalysts – and therefore modern fuels – flowing.

References and Reading Material

Rare Earths in Petroleum Refining & Catalysts - Use and Recovery

Rare Earths in Magnets, EV Motors, Batteries & E-Waste

Rare Earth Recycling, Spent Catalysts & System-Level Context

Suggested Reading Order for Building a Whole-System Argument

Are EV's bad for the environment?

Looking at Bayan Obo (Inner Mongolia, China) the worlds Rare Earth Mining Area.

Ore / Commodity Approximate Reserves (metric tonnes) Notes
Iron ore (Fe) ≥ 1,500,000,000 t USGS and other studies estimate at least 1.5 billion tonnes of iron ore with an average grade of ~35 wt% Fe.
Rare-earth ore (REE minerals) 35,000,000–100,000,000 t (ore / REE minerals) Various estimates: older USGS work gives ~48–100 Mt as RE2O3 equivalents; other sources quote >35 Mt of REE-bearing ore grading ~3–6 % REO. Dominated by light rare earths (Ce, La, Nd, Pr).
Niobium (as Nb2O5) ~1,000,000–2,200,000 t Published figures range from about 1 Mt to ~2.2 Mt Nb2O5 contained, making Bayan Obo a world-class niobium resource as well as an REE deposit.
Fluorite (CaF2) ~130,000,000 t Often cited as ~130 Mt of fluorite, which makes Bayan Obo simultaneously one of the largest fluorite deposits globally.

Bayan Obo overwhelmingly benefits the fossil-fuel industry more than EVs. Here’s the blunt breakdown. Bayan Obo doesn’t exist because of EVs - it exists because the global petroleum industry consumes massive amounts of lanthanum and cerium every year. The mine’s output profile matches refinery demand far more than EV demand. EVs mostly use neodymium and praseodymium, but they use them once and recycle them. Oil refining consumes its REEs continuously and permanently.

References and Links

Rare Earth Usage and Recyclability: Fossil Fuels vs EVs (Side-by-Side)

In the end, both petrol cars and EVs rely on mined materials, but the difference is what happens to those materials over time. Petroleum refining burns through rare earths continuously, creating waste, environmental damage and community health risks that can’t be undone.

System Approx. % of Global REE Usage REEs per Vehicle (Lifetime) Recyclability
Fossil fuels (petrol/diesel) ~60–70% Continuous REE consumption every year via refining + catalyst waste Almost none
EV (full battery electric) ~10–15% (mostly Nd/Pr magnets) ~1–2 kg of REEs once (in motors) High – magnets and motors are recyclable

Conclusion

It is ignorant to say "electric vehicles are more damaging to the environment than petrol cars", A properly charged EV that uses renewable electricity is was cleaner than a Petrol car.

EVs aren’t perfect, but their rare earths and battery metals sit in a closed loop — they can be recovered, reused and improved with every generation. When you add the sharply lower CO₂ emissions, the removal of tailpipe pollution and the long-term recyclability of motors, magnets and batteries, the direction is obvious.

EVs don’t just shift the problem — they shrink it. As technology improves and recycling scales up, the material footprint of an electric vehicle keeps getting smaller, while the fossil-fuel footprint stays the same every single day. Knowing that, it’s hard not to see which path leads to a cleaner, healthier future.

Regional Disclaimer

Rare-earth usage in petroleum refining varies worldwide. While the United States and European Union have largely moved to rare-earth-free FCC catalysts, many refineries in Singapore, South Korea, Japan, India, and the Middle East still use lanthanum and cerium catalysts. Since Australia imports most of its petrol and diesel from these regions, the REE analysis in this article reflects Australia’s imported fuel supply rather than U.S. or EU conditions.