Towards Sustainable Waste Valorization: A Techno‐Economic Analysis and Life Cycle Assessment for HMF Production From Potato Residues Based on Process Simulation

The transition toward a circular bioeconomy requires sustainable alternatives to fossil‐based platform chemicals. This study investigates the techno‐economic and environmental feasibility of producing 5‐hydroxymethylfurfural (HMF) from potato residues, an abundant agro‐industrial waste in Germany. Using Aspen Plus software (V14), a process simulation was developed for two biorefinery Scales: a small on‐farm biorefinery (100 kg/h feedstock) and a larger urban plant (2000 kg/h). Both concepts were evaluated through techno‐economic analysis (TEA) and life cycle assessment (LCA) following ISO 14040/44 standards. The results indicate that scaling up production reduces the minimum selling price (MSP) of HMF from 22.91 €/kg to 4.86 €/kg due to significant economies of scale. Energy demand was identified as the dominant cost driver, particularly during hydrolysis, dehydration, and purification. The assessment of a numbering‐up strategy indicates that process learning effects and increasing automation have the potential to further reduce the MSP, thereby enhancing the overall economic viability of HMF production. LCA results (ReCiPe 2016 method) showed that climate impacts decrease from 2.7 kg CO 2 eq/kg HMF at Scale 1 to 2.6 kg CO 2 eq/kg HMF at Scale 20. Major environmental hotspots included ethanol production and incineration, sulfuric acid use, and sodium hydroxide production. The study shows that potato residues offer a viable, low‐cost feedstock for HMF production, supporting waste valorization and sustainable platform chemical manufacturing. However, pilot‐scale validation is required to confirm process robustness and marketability.