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Abstract Polyethylene furandicarboxylate (PEF) is a novel bio‐based replacement for polyethylene terephthalate (PET). The objective of our study is to improve its economic and environmental competitiveness by applying superstructure‐based pathway optimization, process simulation, techno‐economic analysis, and life‐cycle assessment for the industrial‐scale PEF production. A PEF production pathway that fully utilizes second‐generation biomass is proposed. The mass balance analysis indicates that the carbon utilization of second‐generation biomass could reach up to 21.4%. We found that this production pathway can economically compete with fossil‐based polyethylene terephthalate (PET) under reasonable operating conditions. It achieves over 30% savings in non‐renewable energy use (NREU) and a 38% reduction in carbon emissions. Risk assessment suggests that implementing policies related to NREU and carbon emissions could reduce the investment risk of this PEF production project to less than 20%. This work establishes technical and policy benchmark goals to achieve the economic competitiveness of PEF over PET. 

Abstract We integrate reverse reaction pathway screening, process design and simulation, and process assessment to ensure the technical feasibility, economic viability, and environmental sustainability of biorefineries. We propose an efficient production process for 2‐vinylfuran that fully utilizes second‐generation biomass. Economic assessment indicates that this process can produce 2‐vinylfuran at a competitive cost of $1021 per ton when the production capacity reaches 366 kt/year, supported by reasonable policy initiatives. Sensitivity analysis using Monte Carlo simulations suggests that the investment risk for the 2‐vinylfuran production project could be as low as 26% when scaled up to 500 kt/year. A comparative life cycle assessment highlights significant environmental benefits for 2‐vinylfuran: its production reduces global warming potential (GWP) and non‐renewable energy use (NREU) by over 42% and 30%, respectively, compared to styrene production. Furthermore, the carbon selectivity and carbon yield of the 2‐vinylfuran production process reach as high as 25.2% and 36.2%.