LAUSR

Lignocellulosic biomass processing to produce platform chemicals and biofuels is a promising alternative utilization of non‐renewable resources. This study investigated the techno‐economics of two‐stage and one‐stage furfural production integrated with ethanol co‐production from sugarcane bagasse and harvest residues. The effect of process conditions on profitability was reflected by the minimum ethanol selling price (MESP) at a fixed furfural‐selling price. Aspen Plus V8.8 was used to simulate the integrated two‐stage furfural and ethanol co‐production biorefineries using low (scenario 1), medium (scenario 2) and high (scenario 3) severity steam‐explosion pretreatment. The two‐stage furfural biorefineries integrated with ethanol co‐production were compared with the most profitable one‐stage furfural biorefinery integrated with ethanol co‐production. The required MESP in scenario 2 (0.73 US$ L–1) was decreased by 36% compared with the one‐stage furfural‐ethanol biorefinery (1.14 US$ L–1). Scenarios 1 and 3 were disadvantaged by lower ethanol yields (150 versus 214 kg t–1 of feed) and higher capital investments (322–340) compared with scenario 2 (310 million US$). The one‐stage furfural production had higher heating demands (2034 versus 741–1124 kW t–1 feed) and reduced ethanol yields (90 versus 150–214 kg t–1 of feed) compared with integrated two‐stage furfural and ethanol coproduction biorefineries. Optimization of process conditions, improving energy efficiency, and maximizing productivity within these energy self‐sufficient facilities were critical to minimizing the MESPs, regardless of associated increases in capital and operational costs. © 2021 Society of Chemical Industry and John Wiley & Sons, Ltd