Microwave-Accelerated Reaction Kinetics Enable Low-Carbon and Economic Production of 5-Hydroxymethylfurfural from Sustainable Biomass

5-Hydroxymethylfurfural (HMF), a key biobased platform chemical, can be sustainably produced from fructose, but conventional methods face challenges such as long reaction times, complex solvents, low energy efficiency, and batch-mode operation. This work proposed a continuous microwave (MW)-assisted process for HMF production from fructose, integrating MW-assisted synthesis, solvent recycling, product separation, and combined heat and power (CHP) utilization. Kinetic parameters for the MW process were established and validated, and a continuous process was simulated using Aspen Plus. For comparison, a conventional heating (CH) was also developed, and the energy, economic, and environmental impacts were evaluated. MW irradiation significantly enhanced the reaction rate, enabling a reduced reaction time and reactor volume. As a result, energy consumption decreased by 34% (13.45 MJ/kgHMF), and the HMF production cost was reduced by 23% (1843 USD/tHMF) compared to the CH process. Sensitivity analysis identified HMF yield as a key factor, enabling its improvement to 80% and reducing the cost to 900 USD/tHMF. Additionally, with CHP carbon credits, the MW process reduced the carbon footprint to 9.254 kgCO 2 e/kgHMF. This work demonstrates a rapid, low-carbon, and cost-effective continuous MW-assisted route for HMF production, providing a scalable and electrified solution for sustainable biorefineries.