Production of furanics from sugarcane bagasse via the 5-chloromethylfurfural pathway: techno-economics and greenhouse gas assessment

Abstract

This study investigated the commercial-scale production of furan-based chemicals (furanics) from sugarcane bagasse, using 5-chloromethylfurfural (CMF) as an intermediate platform molecule for the production of bio-based chemicals and materials. A process was developed to convert sugarcane bagasse from a co-located sugar mill to CMF and subsequently upgrade it to 5-methylfurfural (5-MF) or 2,5-dimethylfuran (DMF) to recover the chlorine and recycle as HCl back into the process. The economics and environmental factors for a production facility processing 237,600 t bagasse per annum were investigated. The total capital investment for CMF production is estimated at $63 million, for 5-methylfurfural production at $104 million, and for 2,5-dimethylfuran production at $135 million. The minimum selling price (MSP) for CMF is $0.97/kg; for 5-methylfurfural is $1.68/kg; and for 2,5-dimethylfuran is $2.76/kg. Sensitivity analysis reveals that the minimum selling price of CMF is significantly influenced by the CMF yield, costs of hydrochloric acid (HCl), feedstock, and utilities. The use of HCl also poses a technical and environmental challenge for recycling due to the existence of an azeotrope with water. Greenhouse gas (GHG) emissions of production were calculated to be 1.63 kgCO2-eq/kg CMF, 1.28 kgCO2-eq/kg 5-methylfurfural and 2.50 kgCO2-eq/kg 2,5-dimethylfuran, largely contributed to by HCl use. Therefore, process improvements targeting HCl use reduction are recommended. Solvent-free upgrading to furanic derivatives is proposed to reduce separation costs and improve process efficiency. Despite current challenges, the results demonstrate that CMF can serve as a sustainable and economically attractive route for producing bio-based furanics, showing potential for competitiveness with 5-(hydroxymethyl)furfural-based pathways.