Unlocking the Potential of Biomass Resources: A Review on Sustainable Process Design and Intensification

Biomass is a key renewable resource for advancing sustainable and circular energy systems. In contrast to prior reviews that predominantly emphasized well-established biomass types and conventional conversion technologies, this work offers a comparative synthesis that underscores underutilized feedstocks and emerging valorization pathways, providing a strategic perspective for sustainable process development. This review critically examines the current state of high-value-added bioproducts derived from biomass, focusing on their relevance to climate mitigation and resource efficiency. It explores sustainable process design strategies that enhance the environmental and economic performance of biomass conversion. Particular attention is given to recent advances in process intensification, including novel reactor configurations and heat integration techniques. The integration of sustainability assessment tools and multi-objective optimization approaches is analyzed to support data-driven decision-making. Multi-product biorefineries are discussed as central platforms for valorizing diverse feedstocks, supported by emerging models for supply chain integration. Present limitations such as feedstock heterogeneity, infrastructure constraints, and energy coupling challenges are reviewed, along with new opportunities in digitalization, modularization, and policy support. The novelty of this work lies in its cross-sectional synthesis of technologies, methodologies, and system-level strategies, offering a unified framework to unlock the full potential of biomass as a strategic vector for sustainable process development.