Novel Green Strategy to Produce Bio-Based FDCA

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Prof. ZHANG Yajie's team at the Ningbo Institute of Materials Technology and Engineering (NIMTE), Chinese Academy of Sciences (CAS), has developed an innovative oxidation process that converts 5-hydroxymethylfurfural (HMF) into 2,5-furan dicarboxylic acid (FDCA) at a cost competitive with petroleum-based counterparts.

The study was published in Bioresource Technology.

Biomass, one of Earth's most abundant renewable resources, can be catalytically converted into chemicals and fuels that serve as sustainable alternatives to fossil resources, playing a crucial role in achieving carbon neutrality.

FDCA is currently considered the only bio-based aromatic dicarboxylic acid chemical, with industrialization potential rivaling that of petrochemical-based terephthalic acid (TPA). However, its industrial development has been constrained by high production costs. In addition to the expensive raw material HMF, the oxidation process itself contributes significantly to the overall cost.

Through over a decade of dedicated effort, researchers at NIMTE developed an engineered NaClO/KBr/TEMPO-based oxidation process for converting HMF to FDCA.

They thoroughly analyzed the oxidation mechanism, successfully validated the process at a 100-metric-ton pilot scale, and assessed its economic and technical feasibility for 100,000-metric-ton operations.

Using water as a solvent, this oxidation process achieves a near-100% yield of FDCA from HMF.

Building on this process, along with upstream and downstream industries, the team proposed a three-chain coupling strategy integrating photovoltaics, chlor-alkali, and FDCA. Photovoltaics supply green energy to both the chlor-alkali industry and the FDCA oxidation. In return, the waste salt (NaCl) generated from FDCA electrolysis in the chlor-alkali industry serves as the feedstock for FDCA oxidation, which also helps resolve the solid waste issue from the reaction.

At an annual production scale of 100,000 metric tons, the theoretical cost of FDCA is projected to be approximately $721-$1,101 per ton, closing the cost gap with petroleum-based TPA.

By coupling FDCA production with China's photovoltaic and chlor-alkali sectors, the strategy simultaneously delivers green energy use and green products across the entire process, offering new insights for the transformation and upgrading of the traditional chlor-alkali industry.