Sustainable Production of 2,5-Furandicarboxylic Acid via Nickel-Based Heterogeneous Catalysis from 5-Hydroxymethylfurfural

2,5-Furandicarboxylic acid (FDCA) is a bio-based platform chemical with high potential to replace terephthalic acid in polymer production, particularly for polyethylene furanoate (PEF), a biopolymer with superior thermal and barrier properties. This study investigates the selective oxidation of 5-hydroxymethylfurfural (HMF) into FDCA using nickel-based heterogeneous catalysts, aiming at a cost-effective and sustainable alternative to noble metal catalysts. A series of nickel oxide catalysts were synthesized and screened. The NiOx catalyst synthesized without thermal treatment via Route B showed the best performance, achieving a FDCA yield of 11.77%, selectivity of 27.41%, and concentration of 0.9 g/L under preliminary conditions. Reaction kinetics revealed that the controlled addition of NaClO enhanced FDCA yield by 2.28 times. Optimization using a 2³ factorial design identified the optimal conditions as 6% (w/v) catalyst concentration, 25 °C, and a NaClO:HMF molar ratio of 12:1, leading to 34.14% yield and 42.57% selectivity. The NiOx catalyst maintained its activity over five successive cycles, indicating good recyclability. Moreover, NiOx demonstrated catalytic activity with crude HMF derived from glucose dehydration, confirming its practical applicability. These results support the potential of nickel-based catalysts in sustainable FDCA production, contributing to the advancement of bio-based polymer synthesis.