keyval is very tricky son of a compiler!
I've seen problems with non printable characters (e.g. new lines or spaces) or with national characters. I personally had problem with bibliography file. For some reason file created from I,librarian under windows was causing problems under linux and vice versa. However bibliography just copied from browser window was working good.
The best way to hunt down the error is creating project step by step
1. create some minimum working example
2. add another elements you need
3. wait for error
4. ???
5. PROFIT!
The reason might be also some changes in packages so try to disable as much as you can and add them gradually.
I wish you luck!