Characterizing the potential for sustainable azelaic acid production from high-oleic vegetable oil using the two-step oxidative cleavage method

Azelaic acid is a renewable monomer conventionally produced via energy-intensive ozonolysis of oleic acid. Recent advancements have enabled the use of high-oleic vegetable oils (rather than tallow-derived oleic acid) and replaced ozonolysis with a two-step oxidative cleavage using hydrogen and oxygen. Although this shift would improve process safety, the financial viability and environmental implications remain uncertain. In this study, we characterized the sustainability of azelaic acid production from high oleic vegetable oil using two-step oxidative cleavage. Process design, simulation, techno-economic analysis (TEA), and life cycle assessment (LCA) were executed under uncertainty using BioSTEAM. The modeled system produces azelaic acid at a market-competitive minimum selling price (MSP) of 8.32 [4.93–13.34] $·kg-1 (median 5th–95th percentiles), below the minimum estimated market price of 9.93 $·kg-1. Further, it has the potential to approach carbon neutrality (0.0 [-5.5 to 5.6] kg CO₂-eq·kg-1) under displacement allocation. Improvements to dihydroxylation (86% to 99%) and oxidative cleavage conversions (93% to 99%) would reduce MSP to $5.24·kg-1 and carbon intensity to -1.90 kg CO₂-eq·kg-1 (displacement). Additionally, increasing feedstock triolein content (75% to 85%) lowers MSP by $0.82·kg-1. Overall, this research demonstrates the potential for financially viable azelaic acid production from vegetable oils and the utility of agile TEA/LCA.