Sustainability and Economic Boundaries of Micellar Catalysis in Fine Chemical Synthesis

Abstract

Aqueous surfactant-based systems have emerged as promising media for fine chemical synthesis, offering a sustainable alternative to traditional organic solvents. In these systems, water serves primarily as a dispersing phase, while chemical transformations take place within the hydrophobic cores of self-assembled micelles that concentrate reactants and catalysts in an organic-like microenvironment. Despite significant progress in this area, most existing studies have focused on the assessment of individual reactions or isolated case studies, often under laboratory conditions. As a result, a comprehensive quantitative evaluation of micellar catalysis across multiple industrially relevant processes has remained elusive. Yet, such a comparative approach is essential to capture the diversity of chemistries, reaction environments, and surfactant systems that define the true potential and limitations of micellar media. Here, we present the first integrated techno-economic and life-cycle assessment comparing six representative industrial processes performed under optimized micellar and conventional conditions. Eighteen environmental impact categories were quantified and interpreted within the planetary boundaries framework, together with key economic indicators such as capital, operational, and raw material costs. While certain organic solvent-based routes currently show lower environmental burdens in specific categories, the analysis identifies the main technological and material hotspots that limit micellar systems today and outlines clear pathways to enhance their sustainability and scalability. Overall, this work establishes a quantitative foundation for guiding the next generation of aqueous micellar processes toward truly sustainable chemical manufacturing.