How Renewable Acrylic Acid is Produced
Key Pathways:
- Lactic Acid Dehydration
- Lactic acid (from sugar fermentation) is catalytically dehydrated into acrylic acid using zeolites or phosphates.
- The most advanced and scalable pathway with commercial viability.
- Glycerol Oxidation Route
- Crude glycerol (from biodiesel) is oxidized to acrolein, which is then converted to acrylic acid — mirroring fossil routes.
- 3-Hydroxypropionic Acid (3-HP) Route
- Sugars are fermented to 3-HP, which is dehydrated into acrylic acid. Highly selective but still at early-stage development.
Feedstocks: Sugarcane-derived lactic acid, corn glucose, biodiesel glycerol, lignocellulose-derived sugars.
Case Study: Cargill and NatureWorks – Lactic Acid to Bio-Acrylic Acid
Highlights:
- Cargill collaborated with research partners to convert fermentation-derived lactic acid into bio-based acrylic acid.
- Achieved high-yield catalytic dehydration while ensuring polymer-grade purity for SAPs.
Timeline & Outcome:
- 2011: Lactic acid dehydration research begins with partners like OPX Biotechnologies.
- 2014: Pilot-scale bio-acrylic acid successfully synthesized from lactic acid.
- 2022: Cargill and NatureWorks announce renewed investment in bio-acrylic acid scale-up, aiming to replace fossil AA in hygiene products.
Global Startups Working on Renewable Acrylic Acid
- Cargill (USA) – Developing lactic acid-based bio-AA route in partnership with NatureWorks.
- Nippon Shokubai (Japan) – Working on glycerol-to-AA via acrolein using biodiesel byproducts.
- LG Chem (South Korea) – Investing in bio-acrylic acid for SAPs used in diapers and hygiene products.
- BASF & Cargill JV – Recently announced a dedicated push for bio-AA production via renewable intermediates.
India’s Position
India has large-scale lactic acid production (e.g., Godavari Biorefineries, Indian Glycols), and extensive biodiesel production, making it well-suited for:
- Lactic-to-AA R&D: Limited research at CSIR–NCL Pune and IIT Guwahati is exploring catalytic dehydration of lactic acid.
- Glycerol Pathway Potential: India’s biodiesel plants produce crude glycerol, a promising feedstock for the acrolein pathway.
However, no Indian startup is yet commercializing bio-AA, despite growing local demand for SAPs and hygiene applications.
Commercialization Outlook
Market & Demand
- Global acrylic acid market: ~$13 billion (2024), projected to reach ~$19 billion by 2030.
- Applications:
- Hygiene products (SAPs)
- Paints and coatings
- Textiles, adhesives, sealants
Key Drivers
- Growing pressure to decarbonize consumer goods, especially baby care and hygiene.
- Surging demand for low-VOC and sustainable paints and adhesives.
- Increasing commercial production of fermentation-based lactic acid.
- Glycerol valorization from biodiesel as part of circular bioeconomy.
Challenges to Address
- Thermal Instability: Acrylic acid is volatile and corrosive, requiring careful purification.
- Catalyst Durability: Lactic acid dehydration catalysts degrade quickly under thermal load.
- Yield and Selectivity: Glycerol and 3-HP routes still need process improvement.
- Cost Gap: Bio-AA remains ~20–40% more expensive than fossil-based AA.
Progress Indicators
- 2011–2014: Cargill and partners pilot lactic-to-acrylic acid with encouraging yields.
- 2018–2022: Nippon Shokubai and LG Chem advance glycerol route for hygiene-grade AA.
- 2023–2024: Cargill-NatureWorks and BASF-JV aim for commercial rollout of bio-AA in superabsorbents.
- India: No commercial players yet; academic efforts focused on catalyst development.
TRL 6–7 (pilot to early demonstration). Glycerol-to-AA via acrolein is at TRL 6–7 with multiple ongoing industrial pilots. 3-HP dehydration is at TRL 4–5, mainly lab-scale.
Conclusion
Bio-based acrylic acid is one of the most sought-after molecules for sustainable hygiene and coatings applications. With lactic acid dehydration emerging as the leading pathway, and glycerol-based routes showing complementary promise, global players are pushing toward commercial-scale deployment. While India has the feedstock and fermentation expertise, it has yet to enter this niche. As catalyst efficiencies improve and the cost gap narrows, renewable acrylic acid is poised to transform the SAP, adhesives, and coatings sectors into low-carbon supply chains.
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