Adipic Acid from Biobased Feedstocks

Adipic acid is a key dicarboxylic acid used in the production of nylon-6,6, polyurethanes, plasticizers, and performance coatings. Conventionally synthesized from petro-derived benzene through nitric acid oxidation, it is associated with significant greenhouse gas (GHG) emissions—particularly nitrous oxide (N₂O), a potent climate pollutant.

Bio-based production of adipic acid offers a sustainable alternative by leveraging renewable carbon sources such as glucose, lignocellulosic biomass, glycerol, and fatty acids. While synthetic biology plays a central role, chemical catalysis, fermentation optimization, and hybrid bioprocesses are also contributing to scalable, eco-friendly adipic acid production.

This blog outlines key production pathways, case studies, commercial players, and market outlook for renewable adipic acid.

How Bio-based Adipic Acid Is Produced

Multiple technological pathways are being pursued for sustainable adipic acid synthesis:

1. Fermentative Pathways (Synthetic Biology Enabled)

• Engineered microbes (E. coli, C. glutamicum, Saccharomyces) convert sugars into intermediates like:
• cis,cis-muconic acid, then hydrogenated to adipic acid
• 5-ketoadipic acid or glutaric acid, followed by chain extension
• Feedstocks: Glucose, glycerol, or hydrolyzed biomass
• Key enzyme pathways:
• Shikimate pathway → Muconic acid → Adipic acid
• TCA-cycle rerouting for ketoadipate production

2. Chemical Conversion Pathways

• Hydrothermal or catalytic oxidation of platform chemicals:
• Glucaric acid → Adipic acid
• Levulinic acid → Adipic acid
• Catalysts: Ru/C, Pd-based, or mixed metal oxides under moderate conditions

3. Hybrid Biochemical Routes

• Fermentation of biomass to intermediate (e.g., muconic acid)
• Followed by chemical hydrogenation using green catalysts

4. Bio-derived Butadiene Route

• Bio-butanediol (BDO) or bio-butadiene can be dimerized and oxidized chemically to adipic acid.

Case Study: Genomatica + Cargill (Biobased Adipic Acid Partnership)

Genomatica and Cargill announced a JV in 2021 to produce bio-adipic acid via fermentation of sugars using engineered microbial strains.

Highlights:

• Targeting drop-in replacement for nylon-6,6 production
• Fermentation-based production from dextrose (corn sugar)
• Downstream hydrogenation to high-purity adipic acid

Timeline & Outcome:

• 2021: Partnership announced with pilot-scale validation
• 2023: Progress toward demonstration-scale runs
• 2025 (Expected): First commercial plant targeting nylon-6,6 manufacturers

Case Study: Verdezyne

Verdezyne (USA) used yeast to convert vegetable oil by-products (glycerol) into adipic acid via β-oxidation pathway.

• Produced bio-adipic acid with 85% lower GHG emissions than conventional process
• Commercial plant in Malaysia initiated but later halted due to funding and market challenges

Global Startups & Industry Players

Commercialization Outlook

Market Potential:

• Global adipic acid market: $5.4 billion in 2024; projected to reach $7.6 billion by 2032 (CAGR ~4.3%)
• Applications:
• 60% → Nylon-6,6 (textile, automotive, industrial)
• Rest → Polyurethanes, resins, lubricants, coatings

Demand Drivers:

• Sustainability mandates in textiles, automotive, and coatings
• Pressure to reduce N₂O emissions from nitric acid-based synthesis
• Integration with bio-nylon and green supply chains

Key Challenges

1. Process Economics
• Bio-adipic acid: $3–5/kg vs. conventional: $1.5–2/kg
• Hydrogenation steps increase cost and complexity
2. Intermediate Yield
• Muconic acid and ketoadipate require high titers and conversion efficiencies
• Low flux due to competing pathways in host metabolism
3. Catalyst & Process Integration
• Selective hydrogenation of muconic acid is metal- and pH-sensitive
• Coupling biological and chemical steps at scale remains difficult
4. Feedstock Flexibility
• Lignocellulosic feedstocks pose challenges in sugar purity, inhibitor removal, and cost
5. Infrastructure & Adoption
• Nylon producers require long-term price parity and purity guarantees
• Existing supply chains are tuned to petroleum-based feedstocks

Progress Indicators 

TRL: 6–7
Bio-based adipic acid is at pilot to early demo scale, with some players nearing commercialization. However, technical hurdles in feedstock integration and cost remain for broader adoption.

Conclusion

Adipic acid is a cornerstone chemical for nylon and other polymers—and its bio-based production offers a transformative sustainability opportunity. While synthetic biology-led fermentation is a promising route, hybrid and catalytic approaches are also evolving to meet cost and performance targets.

Companies like Genomatica are driving momentum through integrated sugar-to-adipic acid platforms, yet hurdles such as process economics, strain optimization, and hydrogenation efficiency remain to be solved. As policy and demand push for low-emission nylon, scalable, renewable adipic acid could become a mainstream alternative—especially in regions like India with abundant biomass and growing bio-industrial capabilities.

Wish to have bio-innovations industry or market research support from specialists for climate & environment? Talk to BioBiz team – Call Muthu at +91-9952910083 or send a note to ask@biobiz.in