Lignocellulosic biomass has emerged as a potentially attractive renewable energy source. Processing technologies of such biomass, particularly its primary separation, still lack economic justification due to intense energy requirements. Establishing an economically viable and energy efficient biorefinery scheme is a significant challenge. In this work, a systematic approach is proposed for improving basic/existing biorefinery designs. This approach is based on enhancing the efficiency of mass and energy utilization through the use of a hierarchical design approach that involves mass and energy integration. The proposed procedure is applied to a novel biorefinery called Organocat to minimize its energy and mass consumption and total annualized cost. An improved heat exchanger network with minimum energy consumption of 4.5 MJ/kg(dry biomass) is designed. An optimal recycle network with zero fresh water usage and minimum waste discharge is also constructed, making the process more competitive and economically attractive. (C) 2015 Elsevier Ltd. All rights reserved.