The present work reports a standalone integrated scheme for the production of 5-hydroxymethyl furfural (HMF) and potassium sulphate (K2SO4) from granular biomass rich in the sulphated polysaccharide, κ-carrageenan. Fresh Kappaphycus alvarezii seaweed was crushed to expel the juice rich in KCl (0.7 m3 t−1 of fresh seaweed) and granular biomass (0.04 t dry weight per t of fresh seaweed). The latter yielded κ-carrageenan through seawater extraction. HMF was derived from this phycocolloid through reaction with Mg(HSO4)2 acid catalyst and isolated in pure form. Galactose was a co-product which remained in the aqueous phase. The aqueous phase was recycled up to 10 times by maintaining a constant acid strength, and utilized thereafter for the recovery of K2SO4. Selective crystallization of K2SO4 was guided by the phase diagram and use was made of a part of the seaweed juice in this process. The spent aqueous phase rich in galactose was subjected to further reaction with HCl obtainable through bipolar electro-dialysis (ED) of seaweed juice. The reaction yielded levulinic acid (LA) and formic acid (FA) in nearly equal proportions. The processing of 1 t of granular biomass was computed to require 30.15 GJ of energy and would yield 0.18 t HMF, 0.056 t LA, 0.020 t FA, 0.27 t K2SO4, and 5.77 m3 pure water. The process energy requirement for the scheme can be met from additional supplies of granule (3.35 t). Combustion/gasification of this biomass would yield additionally 0.74 t glaserite fertilizer and the required amount of H2SO4 for Mg(HSO4)2 preparation.
