Toward Economical and Sustainable Production of Renewable Plastic: Integrative System-Level Analyses

2,5-Furandicarboxylic acid (FDCA) is one of the promising renewable plastic monomers enabling to address several environmental issues, instead of petroleum-based terephthalic acid (TPA). In this study, an integrative process for the co-production of FDCA and furfural as well as activated carbon was developed, and the economic feasibility and environmental sustainability for the proposed process were evaluated. In the proposed process, there were major four catalytic conversion reactions: (1) hydrolysis of biomass to its derivatives (cellulose, hemicellulose, and lignin), (2) dehydration of hemicellulose to furfural, (3) dehydration of cellulose to 5-hydroxymethylfurfural (HMF), and (4) successive oxidation of HMF to FDCA. Particularly, a heat exchanger network coupled with a heat pump was established to minimize the utility consumption, thereby reducing 72 % of the heating requirement. Techno-economic analysis revealed that the minimum selling price of FDCA was $1380 ton⁻¹, which is comparable to that of petroleum-based TPA ($1445 ton⁻¹). Uncertainty analysis using the Monte Carlo simulation method was employed to quantify the risk associated with the unforeseen market condition. From the life-cycle assessment, we observed that the proposed process is more environmentally sustainable than conventional TPA production in terms of climate change and fossil depletion metrics.