Process Intensification for the Production of Furandicarboxylic Acid Topic 10 Subtopic b

The proposed program provides a new biomass conversion technology to produce FDCA, 2,5- furandicarboxylic acid, to replace hydrocarbon chemicals for production of commodity plasticizers and polyester polymers. Using current prices, FDCA can economically replace phthalic anhydride and terephthalic acid, commodity chemicals used for production of large volume phthalate plasticizers and polyester polymers. FDCA is derived from hexose sugars, with 5-hydroxymethylfurfural (HMF) as a key intermediate. Commercial production of FDCA is currently hindered by poor selectivity for the catalytic dehydration of fructose using current catalysts and reaction pathways. The overall goal of the Phase IIA project is to accelerate completion of the commercialization of an innovative technology, Intensified Catalytic and Reactive Distillation, for highly selective production of FDCA from sucrose sugar. Improved process intensification is achieved by: (1) utilization of reactive distillation to remove water generated by the reaction, thereby suppressing degradation reactions and increasing selectivity; (2) development of novel catalysts for use in reactive distillation for hexose dehydration with high selectivity; and (3) catalytic oxidation of HMF to FDCA at very high yield. The ongoing Phase II program is successfully completing the research and development required to commercialize the novel technology for FDCA production at high selectivity. The project has developed new catalysts, and a novel reaction system, which has successfully demonstrated fructose conversion to FDCA with greater than 90% selectivity. The novel technology for FDCA production provides exceptionally attractive economics, with an estimated payout time for a commercial plant investment of less than one year. In the Phase IIA program, research, development, scale up, and commercial validation studies will be completed to accelerate immediate commercialization of the new technology for FDCA production. The catalysts, reaction system, and overall manufacturing process will be optimized to provide low cost, high quality FDCA product. A pilot plant will be constructed and operated to validate the technology, provide design and scale up information for commercial production, and support market development activities. FDCA produced by the new technology will find immediate application for production of non-phthalate bio-plasticizers for polyvinyl chloride, and the production of large volume polyester polymers for fibers, beverage bottles, and other products. This will allow conversion of over 10 billion pounds per year of commodity chemical production from hydrocarbon to a biomass base, resulting in reduced greenhouse gases from consumption from the alternative hydrocarbon use and improving long term U.S. competitiveness in global markets.