From process design to application: kinetics, techno-economic assessment, and polymerization of biomass-derived 1,5-pentanediol

1,5-Pentanediol (1,5-PDO) is a versatile C5 diol widely recognized as a promising renewable building block for the synthesis of high-performance polyesters, polyurethanes, and aliphatic polycarbonates. This work demonstrates the sustainable production of bio-based 1,5-PDO via catalytic hydrogenolysis of tetrahydrofurfuryl alcohol using a non-noble Ni–Co–La mixed oxide catalyst. Reaction kinetics, process design, and techno-economic analysis were integrated to optimize the process, yielding a minimum selling price of 2700 USD t −1 —well below the current commercial price of 1,5-PDO (≈5000 USD t −1 ) and of 1,6-hexanediol (≈3500 USD t −1 ), its petrochemical analogue to be replaced. Experimental validation in a 1 L batch reactor confirmed efficient synthesis and purification of bio-based 1,5-PDO, which was polymerized with 2,5-furandicarboxylic acid (FDCA) to form poly(pentamethylene 2,5-furandicarboxylate) (PPeF). The resulting Bio-PPeF exhibited higher molecular weight and superior mechanical and gas-barrier properties than its petrochemical counterpart (Petro-PPeF), confirming the high purity and reactivity of the renewable monomer. Overall, this study establishes a complete framework—from catalyst to monomer validation—demonstrating the technical and economic feasibility of sustainable 1,5-PDO production for next-generation bio-based plastics. • Zero-order kinetics govern THFA hydrogenolysis under industrial conditions. • Minimum selling price of 1,5-PDO reaches ∼2700 USD t −1 , below market prices. • Integrated process validated from lab scale to 1 L reactor operation • Bio-based 1,5-PDO delivers superior polymer performance than petrochemical 1,5-PDO.