Since the complex petrochemical data have characteristics of multi-dimension, uncertainty and noise, it is difficult to accurately optimize and predict the energy usage of complex petrochemical systems. Therefore, this paper proposes a data envelopment analysis (DEA) integrated artificial neural network (ANN) approach (DEA-ANN). The proposed approach utilizes the DEA model with slack variables for sensitivity analysis to determine the effective decision making units (DMUs) and indicate the optimized direction of the ineffective DMUs. Compared with the traditional ANN approach, the DEA-ANN prediction model is effectively verified by executing a linear comparison between all DMUs and the effective DMUs through the standard data source from the UCI (University of California at Irvine) repository. Finally, the proposed model is validated through an application in a complex ethylene production system of China petrochemical industry. The optimization result and the prediction value are obtained to reduce energy consumption of the ethylene production system, guide ethylene production and improve energy efficiency. (C) 2016 Elsevier Ltd. All rights reserved.