How Bio-based Acrylonitrile is Produced
Key Pathways:
- 3-Hydroxypropionic Acid (3-HP) Route
- Fermentation of sugars yields 3-HP.
- 3-HP is dehydrated and ammoxidized to acrylonitrile using ammonia and air.
- Glycerol to Acrolein to Acrylonitrile
- Biodiesel-derived glycerol is converted to acrolein, followed by ammoxidation to acrylonitrile.
- Direct one-pot catalytic processes are under development to simplify this route.
- Lactic Acid Route (Experimental)
- Lactic acid is deoxygenated to intermediates like acrylic acid, then converted to acrylonitrile via amination and dehydration.
Feedstocks: Glucose, fructose, glycerol, molasses, or lignocellulosic hydrolysates.
Case Study: BioAmber & OPX Biotechnologies → Licensed to INEOS
Highlights:
- OPX Biotechnologies developed a 3-HP fermentation platform.
- Partnered with BioAmber to convert 3-HP into bio-acrylonitrile via dehydration and ammoxidation.
- Licensed the technology to INEOS, the world’s largest acrylonitrile producer.
Timeline & Outcome:
- 2014: OPX–BioAmber demo-scale production of 3-HP.
- 2015: INEOS licenses the full bio-ACN process.
- 2017–2021: Ongoing integration with existing acrylonitrile assets.
- 2024: INEOS evaluates commercial-scale deployment at its European facilities.
Global Startups Working on Bio-based Acrylonitrile
- Sestec (Turkey/USA) – Developing bio-glycerol to acrylonitrile routes using hybrid catalysis.
- INEOS Bio – Integrating bio-ACN into carbon fiber and ABS production in collaboration with sustainability-focused OEMs.
- AFYREN (France) – Produces bio-intermediates like propionic acid and acrylic acid, relevant to acrylonitrile chains.
India’s Position
India has large glycerol availability (~400 KTPA) from biodiesel and strong fermentation expertise.
- IITs (Madras, Bombay, Guwahati) and CSIR–IICT have published routes for glycerol to acrolein and acrylic acid.
- India’s demand for acrylonitrile is rising due to the ABS and synthetic fiber sectors, which are import-dependent.
- No domestic bio-ACN production yet, but feedstock and R&D base are highly favorable.
Commercialization Outlook
Market & Demand
- Global acrylonitrile market: ~$13 billion (2024), projected to exceed $18 billion by 2030.
- Major applications:
- Acrylic fibers
- ABS (Acrylonitrile-Butadiene-Styrene) plastics
- Carbon fiber precursors
- Nitrile gloves and elastomers
Key Drivers
- Volatility of propylene prices and fossil feedstock supply.
- OEM interest in carbon-negative carbon fiber for EVs and aerospace.
- Overproduction of glycerol from biodiesel and oleochemical industries.
- Interest in drop-in replacement chemicals for existing Sohio infrastructure.
Challenges to Address
- Catalyst Complexity: Ammoxidation of biobased intermediates needs durable, selective catalysts.
- Process Integration: Matching existing plant conditions for bio-ACN routes.
- Cost Differential: Bio-ACN is still ~20–30% more expensive than petro-ACN.
- Feedstock Variability: Especially for glycerol purity and biomass-based sugars.
Progress Indicators
- 2014–2015: OPX–BioAmber 3-HP to acrylonitrile process reaches pilot stage.
- 2015: INEOS licenses the technology for future integration.
- 2020–2023: Glycerol-based catalytic studies ramp up in EU labs and India.
- 2024: INEOS begins evaluating commercial-scale biobased ACN production.
- India: Ongoing CSIR pilot efforts on glycerol to acrolein to acrylonitrile.
TRL 6–7, with pilot-to-demonstration scale processes proven via fermentation and chemical conversion. Large-scale deployment is in progress by players like INEOS.
Conclusion
Bio-based acrylonitrile is a game-changing innovation for decarbonizing synthetic fibers, ABS plastics, and high-performance materials like carbon fiber. INEOS’s licensing of the BioAmber/OPX platform marks a major industrial validation of this pathway. India, with its abundant glycerol, strong fermentation expertise, and growing demand for ACN derivatives, can build a localized bio-ACN value chain. As catalyst efficiency improves and integration costs fall, bio-acrylonitrile is set to redefine the future of sustainable materials in sectors ranging from textiles to aerospace.
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