Lignocellulosic feedstock materials are the most abundant renewable bioresource material available on earth. It is primarily composed of cellulose, hemicellulose, and lignin, which are strongly associated with each other. Pretreatment processes are mainly involved in effective separation of these complex interlinked fractions and increase the accessibility of each individual component, thereby becoming an essential step in a broad range of applications particularly for biomass valorization. However, a major hurdle is the removal of sturdy and rugged lignin component which is highly resistant to solubilization and is also a major inhibitor for hydrolysis of cellulose and hemicellulose. Moreover, other factors such as lignin content, crystalline, and rigid nature of cellulose, production of post-pretreatment inhibitory products and size of feed stock particle limit the digestibility of lignocellulosic biomass. This has led to extensive research in the development of various pretreatment processes. The major pretreatment methods include physical, chemical, and biological approaches. The selection of pretreatment process depends exclusively on the application. As compared to the conventional single pretreatment process, integrated processes combining two or more pretreatment techniques is beneficial in reducing the number of process operational steps besides minimizing the production of undesirable inhibitors. However, an extensive research is still required for the development of new and more efficient pretreatment processes for lignocellulosic feedstocks yielding promising results.

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This paper presents a comprehensive techno‐economic evaluation of an integrated natural deep eutectic solvent (NADES)‐based biorefinery – a 1 ton day−1 capacity design plant. The key parameters include payback period, net present value (NPV), and internal rate of return (IRR). These were compared with the parameters of conventional biorefineries. The ‘nth plant’ results clearly revealed that the single product‐based biorefinery is not a sustainable approach. Hence, value‐added products viz., cellulose, lignin, xylan, silica, etc., play a vital role in the cost‐effectiveness of bio‐based biorefineries. Based on ‘base‐case’ experimental results, a pilot‐scale plant design scenario is most feasible, with a NPV of 1.4 million USD, >100% IRR, and a payback period of <2 years. Sensitivity analysis revealed that lignin has the greatest impact on revenue. This report proves that multi‐product biorefineries provide better sustainability. The concepts of solvent recycling and reuse, and key challenges to the commercialization of this design approach, were also discussed. The application of NADES in biorefineries, has several advantages, making the implementation of NADES a key feature for increased sustainability in this industry. © 2020 Society of Chemical Industry and John Wiley & Sons, Ltd

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