One of the fundamental challenges in developing biorefineries and sustainable materials is high-value lignin extraction while preserving high-quality cellulosic fiber properties. This work presents a novel biomass fractionation process for efficiently extracting lignin from wheat straw, utilizing a sophisticated approach with minimal solvent loss. The biomass pretreatment was subjected to deep eutectic solvent based delignification under a factorial combination of treatment conditions (e.g. Time, temperature, solvent composition). Additionally, post-treatments that incorporates different approaches for lignin separation and solvent recovery while reducing thinning and washing agents consumption compared to traditional filtration methods. According to experimental findings, a high lignin output with exceptional purity can be achieved while maintaining the mechanical and chemical integrity of the residual pulp by regulating temperature and cooking duration. The filter press is a highly scalable method for industrial applications, offering enhanced lignin recovery rates, shorter processing times, and lower energy consumption compared to conventional filtration. A promising alternative for biomass-based biorefineries, this novel method creates a sustainable and profitable pathway for the manufacture of high-quality pulp and lignin valorization. The results have significant implications for the paper, biofuel, and biopolymer industries, as well as for advancing green chemistry and sustainable material processing.
