A comprehensive optimization model that can determine the most cost-effective and environmentally sustainable production pathways in an integrated processing network is needed, especially in the bioconversion space. We develop the most comprehensive bioconversion network to date with 193 technologies and 129 materials/compounds for fuels production. We consider the tradeoff between scaling capital and operating expenditures (CAPEX and OPEX) as well as life cycle environmental impacts. Additionally, we develop a general network-based modeling framework with nonconvex terms for CAPEX. To globally optimize the nonlinear program with high computational efficiency, we develop a specialized branch-and-refine algorithm based on successive piecewise linear approximations. Two case studies are considered. The optimal pathways have profits from 2$12.9 to $99.2M/yr, and emit 791 ton CO 2 -eq/yr to 31,571 ton CO 2 -eq/yr. Utilized technologies vary from corn-based fermentation to pyrolysis. The proposed algorithm reduces computational time by up to three orders of magnitude compared to general-purpose global optimizers. V C 2014 American Institute of Chemical Engineers AIChE J, 61: 530-554, 2015Green steps denote final solution steps, yellow denote checking steps, red steps denote that another iteration is needed, and blue denotes solving an MILP with the SOS1 formulation. UB 5 upper bound, LB 5 lower bound. [Color figure can be viewed in the online issue, which is available at wileyonlinelibrary.com.]
540Hardwood is converted via gasification and subsequent upgrading to gasoline. [Color figure can be viewed in the online issue, which is available at wileyonlinelibrary.com.]