In this research article, application of artificial neural network (ANN) and response surface methodology (RSM) is employed to predict the extraction yield (EY) of bio-oil from the pyrolysis of Mangifera indica wood (MIW) sawdust, developing the two optimized models (i.e., ANN-FFBP and RSM-CCD). The effect of three input parameters with their ranges, viz. particle size (0.2–0.8 mm), temperature (430–630 °C), and N2-gas flow rate (60–160 mL/min) on EY of MIW bio-oil are investigated. The Levenberg–Marquardt (LM) algorithm is used to train the network and an ANN-FFBP based model is developed for predicting the EY. Sensitivity analysis confirmed the superiority of optimal ANN-FFBP [3–9–1] model over the optimized RSM-CCD model with the values (AARD%= 0.25945, MSE = 0.00001 and R2 = 0.99711). The maximum EY of bio-oil (45.50 mass%) was observed at optimum conditions of parameters (0.6 mm, 564 °C, and 120 mL/min). The analysis of bio-oil through GC–MS confirmed the presence of high-valued compounds, e.g., methylenecyclopropanecarboxylic acid (8.11 mass%) and p-Cresol (11.41 mass%). In addition to this, the commercial significance of the extracted pyrolysis products has been confirmed via FTIR, ignition point, elemental analyzer, 1H NMR, and FE-SEM-EDX. Moreover, the techno-economic assessment of bio-oil production at industrial scale of 10 TPD assured a profit margin of 109–128 % for per kg production of bio-oil.
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