Sustainable Production of Acrylic Acid via 3‑Hydroxypropionic Acid from Lignocellulosic Biomass

Lignocellulosic biomass is a promising renewable feedstock for the sustainable manufacturing of biofuels and bioproducts. Among emerging bioproducts, 3-hydroxypropionic acid (3-HP) is of particular interest as a platform chemical to produce commercially significant chemicals such as acrylic acid. In this study, BioSTEAMan open-source platformwas leveraged to design, simulate, and evaluate (via techno-economic analysis, TEA, and life cycle assessment, LCA) biorefineries producing acrylic acid via fermentation of sugars (glucose and xylose) to 3-HP. The biorefinery could produce acrylic acid with a minimum product selling price (MPSP) of $1.72–2.08·kg–1 (5th–95th percentiles; baseline at $1.83·kg–1). Advancements in key technological parameters (fermentation yield, titer, and saccharification solids loading) could greatly enhance the biorefinery’s performance (MPSP of $1.29–1.52·kg–1 with ∼88% probability of market-competitiveness, a global warming potential of 3.00 [2.53–3.38] kg CO2-eq·kg–1, and a fossil energy consumption of 39.9 [31.6–45.1] MJ·kg–1). A quantitative sustainable design framework was used to explore alternative fermentation regimes (neutral/low-pH fermentation across titer, yield, and productivity combinations) and alternative feedstocks (first/second-generation feedstocks across price and sugar/carbohydrate content). Overall, this research highlights the ability of agile TEA–LCA to screen promising biorefinery designs, navigate sustainability trade-offs, prioritize research needs, and establish a roadmap for the continued development of bioproducts and biofuels.