Critical Evaluation of 2,5-Furandicarboxylic Acid (FDCA) Production from Biomass: Perspectives on Reaction Pathways, Catalytic Systems, and Process Optimization

Abstract

The shift from petroleum-based to renewable chemicals is essential for sustainable production. 2,5-Furandicarboxylic acid (FDCA) is an important bio-based platform chemical for the production of sustainable polymers, particularly polyethylene 2,5-furandicarboxylate (PEF), a promising alternative to fossil fuel-derived polyethylene terephthalate (PET). This review examines the recent advances in catalytic FDCA synthesis from biomass-derived sugars and furan feedstocks. Specifically, it investigates one-pot catalytic systems that integrate multiple reaction steps, including hydrolysis, isomerization, dehydration, and oxidation, into a single system to improve efficiency and reduce process complexity. Building on this, the review analyzes the reaction kinetics of bio-based feedstocks and proposes possible reaction pathways for FDCA synthesis, providing new insights into the rate-limiting steps and evaluating advanced mono-and bimetallic catalysts for enhanced selectivity and conversion. Beyond synthesis and kinetics, this review details a multivariate assessment approach to systematically evaluate the impact of feedstock type, catalyst composition, and solvent on the FDCA yield, exploring optimization strategies for key process parameters. It then examines the current technological, economic, and scale-up challenges and provides insights into the pathways for FDCA commercialization. Finally, this review outlines future directions for cost-effective, scalable, and green FDCA production. This review advocates multifunctional catalysts, integrated one-pot processes, sustainable solvents, and process intensification strategies, all of which are crucial for advancing the commercial viability of FDCA synthesis as a vital technology in the transition toward a circular, bio-based economy.