The process synthesis, technoeconomic analysis, and life cycle assessment (LCA) of a novel route for phthalic anhydride (PAN) production from hemicellulose solutions are presented. The production contains six steps including dehydration of xylose to furfural, reductive decarbonylation of furfural to furan, oxidation of furfural to maleic anhydride (MA), Diels-Alder cycloaddition of furan, and MA to exo-4,10-dioxa-tricyclo[5.2.1.0]dec-8-ene-3,5-dione followed by dehydration to PAN in the presence of mixture of methanesulfonic acid and acetic anhydride (AAN) which is converted to acetyl methanesulfonate and acetic acid (AAD), and dehydration of AAD to AAN. The minimum selling price of PAN is determined to be $810/metric ton about half of oil-based PAN. The coproduction of high-value products is essential to improve the economics. Biomass feedstock contributes to the majority of cost. LCA results shows that biomass-based PAN has advantages over oil-based PAN to reduce climate change and fossil depletion however requires more water usage. (c) 2015 American Institute of Chemical Engineers