Using sulfite chemistry for robust bioconversion of Douglas-fir forest residue to bioethanol at high titer and lignosulfonate: a pilot-scale evaluation

High solids loading pretreatment: The core of lignocellulose biorefinery as an industrial technology - An overview

Pretreatment is the first and most determinative, yet the least mature step of lignocellulose biorefinery chain. The current stagnation of biorefinery commercialization indicates the barriers of the existing pretreatment technologies are needed to be unlocked. This review focused on one of the core factors, the high lignocellulose solids loading in pretreatment. The high solids loading of pretreatment significantly reduces water input, energy requirement, toxic compound discharge, solid/liquid separation costs, and carbon dioxide emissions, improves the titers of sugars and biproducts to meet the industrial requirements. Meanwhile, lignocellulose feedstock after high solids loading pretreatment is compatible with the existing logistics system for densification, packaging, storage, and transportation. Both the technical-economic analysis and the cellulosic ethanol conversion performance suggest that the solids loading in the pretreatment step need to be further elevated towards an industrial technology and the effective solutions should be proposed to the technical barriers in high solids loading pretreatment operations.

Pretreatment Strategies to Enhance Enzymatic Hydrolysis and Cellulosic Ethanol Production for Biorefinery of Corn Stover

There is a rising interest in bioethanol production from lignocellulose such as corn stover to decrease the need for fossil fuels, but most research mainly focuses on how to improve ethanol yield and pays less attention to the biorefinery of corn stover. To realize the utilization of different components of corn stover in this study, different pretreatment strategies were used to fractionate corn stover while enhancing enzymatic digestibility and cellulosic ethanol production. It was found that the pretreatment process combining dilute acid (DA) and alkaline sodium sulfite (ASS) could effectively fractionate the three main components of corn stover, i.e., cellulose, hemicellulose, and lignin, that xylose recovery reached 93.0%, and that removal rate of lignin was 85.0%. After the joint pretreatment of DA and ASS, the conversion of cellulose at 72 h of enzymatic hydrolysis reached 85.4%, and ethanol concentration reached 48.5 g/L through fed-batch semi-simultaneous saccharification and fermentation (S-SSF) process when the final concentration of substrate was 18% (w/v). Pretreatment with ammonium sulfite resulted in 83.8% of lignin removal, and the conversion of cellulose and ethanol concentration reached 86.6% and 50 g/L after enzymatic hydrolysis of 72 h and fed-batch S-SSF, respectively. The results provided a reference for effectively separating hemicellulose and lignin from corn stover and producing cellulosic ethanol for the biorefinery of corn stover.

Benzenesulfonic acid-based hydrotropic system for achieving lignocellulose separation and utilization under mild conditions

Developing low-cost and sustainable fractionation technology is the key to achieve the maximal utilization of lignocellulosic biomass. This study reported benzenesulfonic acid (BA) as a green hydrotrope for efficient lignocellulose conversion into two fractions at atmospheric pressure: (1) a primarily cellulosic solid residue that can be utilized to produce high-value building blocks (lignocellulosic nanomaterials or sugars), and (2) the collected spent acid liquor that can be diluted with anti-solvent to easily obtain lignin nanoparticles. BA hydrotropic method exhibited greater reaction selectivity to solubilize lignin, where approximately 80% lignin were removed at only 80 °C in 20 min. The lower lignin content substrates resulted in relatively higher enzymatic hydrolysis efficiency of 80% and less entangled lignocellulosic nanofibrils (LCNF). Furthermore, the separated lignin particles size can be easily adjusted by the initial acid concentration. Overall, this work presented a promising and simple technology in achieving lignocellulose separation and utilization under mild conditions.

Towards sustainable production and utilization of plant-biomass-based nanomaterials: a review and analysis of recent developments

Plant-biomass-based nanomaterials have attracted great interest recently for their potential to replace petroleum-sourced polymeric materials for sustained economic development. However, challenges associated with sustainable production of lignocellulosic nanoscale polymeric materials (NPMs) need to be addressed. Producing materials from lignocellulosic biomass is a value-added proposition compared with fuel-centric approach. This report focuses on recent progress made in understanding NPMs-specifically lignin nanoparticles (LNPs) and cellulosic nanomaterials (CNMs)-and their sustainable production. Special attention is focused on understanding key issues in nano-level deconstruction of cell walls and utilization of key properties of the resultant NPMs to allow flexibility in production to promote sustainability. Specifically, suitable processes for producing LNPs and their potential for scaled-up production, along with the resultant LNP properties and prospective applications, are discussed. In the case of CNMs, terminologies such as cellulose nanocrystals (CNCs) and cellulose nanofibrils (CNFs) used in the literature are examined. The term cellulose nano-whiskers (CNWs) is used here to describe a class of CNMs that has a morphology similar to CNCs but without specifying its crystallinity, because most applications of CNCs do not need its crystalline characteristic. Additionally, progress in enzymatic processing and drying of NPMs is also summarized. Finally, the report provides some perspective of future research that is likely to result in commercialization of plant-based NPMs.

Recent advances in the valorization of plant biomass

Plant biomass is a highly abundant renewable resource that can be converted into several types of high-value-added products, including chemicals, biofuels and advanced materials. In the last few decades, an increasing number of biomass species and processing techniques have been developed to enhance the application of plant biomass followed by the industrial application of some of the products, during which varied technologies have been successfully developed. In this review, we summarize the different sources of plant biomass, the evolving technologies for treating it, and the various products derived from plant biomass. Moreover, the challenges inherent in the valorization of plant biomass used in high-value-added products are also discussed. Overall, with the increased use of plant biomass, the development of treatment technologies, and the solution of the challenges raised during plant biomass valorization, the value-added products derived from plant biomass will become greater in number and more valuable.

Sustainability metrics of pretreatment processes in a waste derived lignocellulosic biomass biorefinery

Excessive utilization of fossil fuels has resulted in serious concerns about climate change. Integrating biorefinery technology to convert waste-derived-lignocellulosic biomass into biofuels and biopolymers has become an emerging topic toward our sustainable future. Pretreatment to fractionate the building block chemicals from the biomass is a crucial unit operation to ease the downstream processes in biorefinery. However, application of solvents and chemicals in the process can create many operational and environmental challenges in sensitive areas like highly populated cities. To shed light on how to determine a green biorefinery, this study presents the sustainability metrics of various pretreatment techniques and their operational risks during urbanization. The proposed green indexes include fractionation outputs, chemical recyclability, operational profile, and safety factors. In line with the design principles of lignin valorization, the issue of urban biomass and water-and-energy nexus are addressed to support future development and application of urban biorefinery for municipal waste management.

Simultaneous enzymatic saccharification and comminution for the valorization of lignocellulosic biomass toward natural products

Background

Large-scale processing of lignocellulosics for glucose production generally relies on high temperature and acidic or alkaline conditions. However, extreme conditions produce chemical contaminants that complicate downstream processing. A method that mainly rely on mechanical and enzymatic reaction completely averts such problem and generates unmodified lignin. Products from this process could find novel applications in the chemicals, feed and food industry. But a large-scale system suitable for this purpose is yet to be developed. In this study we applied simultaneous enzymatic saccharification and communition (SESC) for the pre-treatment of a representative lignocellulosic biomass, cedar softwood, under both laboratory and large-scale conditions.

Results

Laboratory-scale comminution achieved a maximum saccharification efficiency of 80% at the optimum pH of 6. It was possible to recycle the supernatant to concentrate the glucose without affecting the efficiency. During the direct alcohol fermentation of SESC slurry, a high yield of ethanol was attained. The mild reaction conditions prevented the generation of undesired chemical inhibitors. Large-scale SESC treatment using a commercial beads mill system achieved a saccharification efficiency of 60% at an energy consumption of 50 MJ/kg biomass.

Conclusion

SESC is very promising for the mild and clean processing of lignocellulose to generate glucose and unmodified lignin in a large scale. Economic feasibility is highly dependent on its potential to generate high value natural products for energy, specialty chemicals, feed and food application.

Inhibition of the Exoglucanase Cel7A by a Douglas-Fir-Condensed Tannin

Douglas-fir forestry residues are a potential feedstock for saccharification-based biofuels, and condensed tannins are expected to make up ∼3% of the dry mass of this feedstock. Condensed tannins are well-known for their ability to interact with proteins and can bind and inhibit cellulase enzymes used in saccharification. In this study, we use molecular docking and classical molecular dynamics simulations to investigate how a characterized condensed tannin from Douglas-fir bark binds to the exoglucanase Cel7A from Trichoderma reesei. Through looking at the "occupancy" and "residency" of specific amino acid residue-tannin interactions, we find that the binding sites are characterized by many simultaneous tannin-enzyme interactions with the strongest occurring on the catalytic module as opposed to the carbohydrate-binding module. The simulations indicate that tannin inhibition can result from binding at or near the catalytic tunnel's entrance and exit. The analyzed tannin further prefers to bind to loops around the catalytic region and has affinity for aromatic and charged amino acid residues. These insights provide direction for the rational design of tannin-resistant cellulases.

Preparation of Lignosulfonates from Biorefinery Lignins by Sulfomethylation and Their Application as a Water Reducer for Concrete

Lignosulfonate (LG), a water-soluble polymer from sulfite pulping process of lignocellulosic biomass, has been commercially applied as admixture for concrete. In this work, lignosulfonates were produced from alkaline lignin (AL) and enzymatic hydrolysis residue (EHR) by sulfomethylation and these lignosulfonates as water reducers for concrete were then evaluated. Results showed that 94.9% and 68.9% of lignins in AL and EHR could be sulfonated under optimum sulfomethylation conditions, respectively. The sulfonic groups in lignosulfonates from AL (AL-LG) and EHR (EHR-LG) were 1.6 mmol/g and 1.0 mmol/g, respectively. Surface tension and zeta potential analysis indicated that both AL-LG and EHR-LG can be potentially used to as dispersant for improving the fluidity of the cement paste, similarly to commercial lignosulfonate (CM-LG). Adding 0.2 wt % of AL-LG, EHR-LG, and CM-LG in the concrete, the compressive strength (28 days) of concretes increased from 38.4 Mpa to 41.6, 42.6, and 40.9 Mpa, respectively. These findings suggest that the lignosulfonate from biorefinery lignin by sulfomethylation can meet the industrial standards as water reducers for cement admixtures.

Bioethanol from sugarcane bagasse: Focused on optimum of lignin content and reduction of enzyme addition

To investigate the effect of delignification on enzymatic saccharification and ethanol fermentation of sugarcane bagasse (SCB), NaClO, NaOH, and Na₂CO₃ were used to prepare SCB with different lignin contents. We found that a lignin content of approximately 11% was sufficient for enzymatic saccharification and fermentation. Based on this result, an economical delignification pretreatment method using a combination of acid and alkali (CAA) was applied. Lignin content of 11.7% was obtained after CAA pretreatment with 0.5% w/v H₂SO₄ at 140 °C for 10 min and 1.0% w/v NaOH at 90 °C for 60 min. Presaccharification-simultaneous saccharification and fermentation (P-SSF) of the CAA-pretreated SCB resulted in an ethanol concentration of 43.8 g/L and an ethanol yield of 81.7%, with an enzyme loading of 15 FPU/g-CAA-pretreated SCB. Enzyme activities (filter paper, carboxymethyl cellulase, and β-glucosidase activities) were determined in liquid phase during P-SSF, indicating that the residual cellulase activity could be further used. Thus, fed-batch P-SSF was carried out, and an ethanol concentration of 43.1 g/L and an ethanol yield of 80.4% were obtained with an enzyme loading of 10 FPU/g-CAA-pretreated SCB. Fed-batch P-SSF was found to be effective to reduce enzyme loading.

Increased sugar yield from pre-milled Douglas-fir forest residuals with lower energy consumption by using planetary ball milling

Impact of planetary ball milling on pre-milled wood fiber was studied to improve efficiency of energy consumption for bioconversion using post-harvest forest residuals. Crystalline cellulose decreased from 40.73% to 11.70% by ball milling. Crystallinity index of ball milled wood samples had a negative correlation with glucose yield (r = -0.97, p < .01), xylose/mannose (r = -0.96, p < .01), and a positive correlation with median particle size (r = 0.77, p < .01). Range of glucose yield and xylose/mannose yield for ball milled samples was found to be 24.45-59.67% and from 11.92% to 23.82%, respectively. Morphological changes of the lignocellulosic biomass were observed; the compact fiber bundles of the forest residuals were cleaved to smaller particles with lower aspect ratio with increasing intensity of ball milling. The required energy ranged from 0.50 to 2.15 kWh/kg for 7-30 min of milling respectively.

Xylan extraction from pretreated sugarcane bagasse using alkaline and enzymatic approaches

BACKGROUND

New biorefinery concepts are necessary to drive industrial use of lignocellulose biomass components. Xylan recovery before enzymatic hydrolysis of the glucan component is a way to add value to the hemicellulose fraction, which can be used in papermaking, pharmaceutical, and food industries. Hemicellulose removal can also facilitate subsequent cellulolytic glucan hydrolysis.

RESULTS

Sugarcane bagasse was pretreated with an alkaline-sulfite chemithermomechanical process to facilitate subsequent extraction of xylan by enzymatic or alkaline procedures. Alkaline extraction methods yielded 53% (w/w) xylan recovery. The enzymatic approach provided a limited yield of 22% (w/w) but produced the xylan with the lowest contamination with lignin and glucan components. All extracted xylans presented arabinosyl side groups and absence of acetylation. 2D-NMR data suggested the presence of O-methyl-glucuronic acid and p-coumarates only in enzymatically extracted xylan. Xylans isolated using the enzymatic approach resulted in products with molecular weights (Mw) lower than 6 kDa. Higher Mw values were detected in the alkali-isolated xylans. Alkaline extraction of xylan provided a glucan-enriched solid readily hydrolysable with low cellulase loads, generating hydrolysates with a high glucose/xylose ratio.

CONCLUSIONS

Hemicellulose removal before enzymatic hydrolysis of the cellulosic fraction proved to be an efficient manner to add value to sugarcane bagasse biorefining. Xylans with varied yield, purity, and structure can be obtained according to the extraction method. Enzymatic extraction procedures produce high-purity xylans at low yield, whereas alkaline extraction methods provided higher xylan yields with more lignin and glucan contamination. When xylan extraction is performed with alkaline methods, the residual glucan-enriched solid seems suitable for glucose production employing low cellulase loadings.

Rapid and near-complete dissolution of wood lignin at ≤80°C by a recyclable acid hydrotrope

We report the discovery of the hydrotropic properties of a recyclable aromatic acid, p-toluenesulfonic acid (p-TsOH), for potentially low-cost and efficient fractionation of wood through rapid and near-complete dissolution of lignin. Approximately 90% of poplar wood (NE222) lignin can be dissolved at 80°C in 20 min. Equivalent delignification using known hydrotropes, such as aromatic salts, can be achieved only at 150°C or higher for more than 10 hours or at 150°C for 2 hours with alkaline pulping. p-TsOH fractionated wood into two fractions: (i) a primarily cellulose-rich water-insoluble solid fraction that can be used for the production of high-value building blocks, such as dissolving pulp fibers, lignocellulosic nanomaterials, and/or sugars through subsequent enzymatic hydrolysis; and (ii) a spent acid liquor stream containing mainly dissolved lignin that can be easily precipitated as lignin nanoparticles by diluting the spent acid liquor to below the minimal hydrotrope concentration. Our nuclear magnetic resonance analyses of the dissolved lignin revealed that p-TsOH can depolymerize lignin via ether bond cleavage and can separate carbohydrate-free lignin from the wood. p-TsOH has a relatively low water solubility, which can facilitate efficient recovery using commercially proven crystallization technology by cooling the concentrated spent acid solution to ambient temperatures to achieve environmental sustainability through recycling of p-TsOH.

A co-production of sugars, lignosulfonates, cellulose, and cellulose nanocrystals from ball-milled woods

This study demonstrated the technical potential for the large-scale co-production of sugars, lignosulfonates, cellulose, and cellulose nanocrystals. Ball-milled woods with two particle sizes were prepared by ball milling for 80min or 120min (BMW₈₀, BMW₁₂₀) and then enzymatically hydrolyzed. 78.3% cellulose conversion of BMW₁₂₀ was achieved, which was three times as high as the conversion of BMW₈₀. The hydrolyzed residues (HRs) were neutrally sulfonated cooking. 57.72g/L and 88.16g/L lignosulfonate concentration, respectively, were harvested from HR₈₀ and HR₁₂₀, and 42.6±0.5% lignin were removed. The subsequent solid residuals were purified to produce cellulose and then this material was acid-hydrolyzed to produce cellulose nanocrystals. The BMW₁₂₀ maintained smaller particle size and aspect ratio during each step of during the multiple processes, while the average aspect ratio of its cellulose nanocrystals was larger. The crystallinity of both materials increased with each step of wet processing, reaching to 74% for the cellulose.

Using a combined hydrolysis factor to balance enzymatic saccharification and the structural characteristics of lignin during pretreatment of Hybrid poplar with a fully recyclable solid acid

In this study, a new pretreatment strategy for lignocellulosic was developed using a fully recyclable solid acid, Toluenesulfonic acid (p-TsOH). A combined hydrolysis factor (CHF) as a pretreatment severity was used to balance enzymatic saccharification and the structural characteristics of lignin. The results from degradation of carbohydrates, enzymatic hydrolysis of cellulose and characterization of lignin by FT-IR, ³¹P NMR, GPC, 2D-HSQC NMR indicated that a CHF of approximately 3.90 was the optimal pretreatment severity to facilitate enzymatic saccharification and the potential serviceability of lignin. Then approximately 90% of the xylan was removed to result in a reasonable sugar yield of 76%. Residual lignin showed low molecular weight (Mw, 5783g/mol), narrow polydispersities (Mw/Mn, 1.10) and high content of phenolic hydroxyl groups (3.702mmol/g); it may be a potential feedstock for phenol monomer and polymeric materials production. In short, this process was regarded as a promising approach to achieve an efficient conversion of lignocellulosic biomass to sugar products and lignin-based materials.

Modeling the production of sugar and byproducts from acid bisulfite pretreatment and enzymatic hydrolysis of Douglas-fir

The aim of this work was to investigate the kinetics of multiple chemicals in acid bisulfite pretreatment and the relationship between total sugar yields and pretreatment factors (temperature and time). The results showed Saeman model accurately fitted the pretreatment process. According to this kinetic model, a maximum hemicellulose hydrolysis yield was achieved at a treatment time of 75min with a temperature of 145°C. Meantime, the concentrations of acetic acid, hydroxymethylfurfural (HMF), and furfural were 1.54, 0.60, and 1.15gL^-1, respectively. Also, a Lorentzian function described the relationship between total sugar yield and pretreatment factors: temperature and time. The regression parameters from this mathematical fitting have accurately reflected the maximum total sugar yield and the optimal treatment conditions were determined to be 145°C and 110min.

Integrated production of furfural and levulinic acid from corncob in a one-pot batch reaction incorporating distillation using step temperature profiling

Integrated production of furfural and levulinic acid (LA) in one pot through two-step temperature profiling.

Oxidative degradation of biorefinery lignin obtained after pretreatment of forest residues of Douglas Fir

Harvested forest residues are usually considered a fire hazards and used as "hog-fuel" which results in air pollution. In this study, the biorefinery lignin stream obtained after wet explosion pretreatment and enzymatic hydrolysis of forestry residues of Douglas Fir (FS-10) was characterized and further wet oxidized under alkaline conditions. The studies indicated that at 10% solids, 11.7wt% alkali and 15min residence time, maximum yields were obtained for glucose (12.9wt%), vanillin (0.4wt%) at 230°C; formic acid (11.6wt%) at 250°C; acetic acid (10.7wt%), hydroxybenzaldehyde (0.2wt%), syringaldehyde (0.13wt%) at 280°C; and lactic acid (12.4wt%) at 300°C. FTIR analysis of the solid residue after wet oxidation showed that the aromatic skeletal vibrations relating to lignin compounds increased with temperature indicating that higher severity could result in increased lignin oxidation products. The results obtained, as part of the study, is significant for understanding and optimizing processes for producing high-value bioproducts from forestry residues.

Effect of acid pretreatment on different parts of corn stalk for second generation ethanol production

In this study, the effects of different parts of corn stalk, including stem, leaf, flower, cob and husk on second generation ethanol production were evaluated. FTIR, XRD and SEM were performed to investigate the effect of dilute acid pretreatment. The bagasse obtained after pretreatment were further hydrolyzed by cellulase and used as the substrate for ethanol fermentation. As results, hemicelluloses fractions in different parts of corn stalk were dramatically removed and the solid fractions showed vivid compositions and crystallinities. Compared with other parts of corn stalk, the cob had higher sugar content and better enzymatic digestibility. The highest glucose yield of 94.2% and ethanol production of 24.0 g L(-1) were achieved when the cob was used as feedstock, while the glucose yield and the ethanol production were only 86.0% and 17.1 g L(-1) in the case of flower.

Conversion of SPORL pretreated Douglas fir forest residues into microbial lipids with oleaginous yeasts

Sugars were extracted from Douglas fir residues using SPORL pretreatment and cellulases. The sugars were converted to lipids producing a titer of 13.4 g l⁻¹ in 3 d using a 2-stage culture.

Efficient Conversion of Lignin to Electricity Using a Novel Direct Biomass Fuel Cell Mediated by Polyoxometalates at Low Temperatures

A novel polyoxometalates (POMs) mediated direct biomass fuel cell (DBFC) was used in this study to directly convert lignin to electricity at low temperatures with high power output and Faradaic efficiency. When phosphomolybdic acid H3 PMo12 O40 (PMo12) was used as the electron and proton carrier in the anode solution with a carbon electrode, and O2 was directly used as the final electron acceptor under the catalysis of Pt, the peak power density reached 0.96 mW cm(-2), 560 times higher than that of phenol-fueled microbial fuel cells (MFCs). When the cathode reaction was catalyzed by PMo12, the power density could be greatly enhanced to 5 mW cm(-2). Continuous operation demonstrated that this novel fuel cell was promising as a stable electrochemical power source. Structure analysis of the lignin indicated that the hydroxyl group content was reduced whereas the carbonyl group content increased. Both condensation and depolymerization takes place during the PMo12 oxidation of lignin.

Using a combined hydrolysis factor to optimize high titer ethanol production from sulfite-pretreated poplar without detoxification

Sulfite pretreatment to overcome the recalcitrance of lignocelluloses (SPORL) was applied to poplar NE222 chips in a range of chemical loadings, temperatures, and times. The combined hydrolysis factor (CHF) as a pretreatment severity accurately predicted xylan dissolution by SPORL. Good correlations between CHF and pretreated solids enzymatic digestibility, sugar yield, and the formations of furfural and acetic acid were obtained. Therefore, CHF was used to balance sugar yield with the formation of fermentation inhibitors for high titer ethanol production without detoxification. The results indicated that optimal sugar yield can be achieved at CHF=3.1, however, fermentation using un-detoxified whole slurries of NE222 pretreated at different severities by SPORL indicated CHF≈2 produced best results. An ethanol titer of 41 g/L was achieved at total solids of approximately 20 wt% without detoxification with a low cellulase loading of 15 FPU/g glucan (27 mL/kg untreated wood).

High titer and yield ethanol production from undetoxified whole slurry of Douglas-fir forest residue using pH profiling in SPORL

BACKGROUND

Forest residue is one of the most cost-effective feedstock for biofuel production. It has relatively high bulk density and can be harvested year round, advantageous for reducing transportation cost and eliminating onsite storage. However, forest residues, especially those from softwood species, are highly recalcitrant to biochemical conversion. A severe pretreatment for removing this recalcitrance can result in increased sugar degradation to inhibitors and hence cause difficulties in fermentation at high solid loadings. Here, we presented high titer ethanol production from Douglas-fir forest residue without detoxification. The strong recalcitrance of the Douglas-fir residue was removed by sulfite pretreatment to overcome the recalcitrance of lignocelluloses (SPORL). Sugar degradation to inhibitors was substantially reduced using a novel approach of "pH profiling" by delaying acid application in pretreatment, which facilitated the simultaneous enzymatic saccharification and fermentation of undetoxified whole slurry at a solid loading of 21%.

RESULTS

"pH profiling" reduced furan production by approximately 70% in using SPORL pretreating Douglas-fir forest residue (FS-10) comparing with the control run while without sacrificing enzymatic saccharification of the resultant substrate. pH profiling also reduced carbohydrate degradation. The improved carbohydrate yield in pretreated solids and reduced fermentation inhibitors with pH profiling resulted in a terminal ethanol titer of 48.9 ± 1.4 g/L and yield of 297 ± 9 L/tonne FS-10, which are substantially higher, i.e., by 27% in titer and by 38% in yield, than those of a control SPORL run without pH profiling.

CONCLUSIONS

Economical and large-volume production of commodity biofuels requires the utilization of feedstocks with low value (therefore low cost) and sustainably producible in large quantities, such as forest residues. However, most existing pretreatment technologies cannot remove the strong recalcitrance of forest residues to produce practically fermentable high titer sugars. Here, we demonstrated a commercially scalable and efficient technology capable of removing the strong recalcitrant nature of forest residues using "pH profiling" together with "low temperature SPORL". The resultant pretreated whole slurry of a Douglas-fir forest residue using this technology can be easily processed at high solids of 21% without detoxification to achieve a high ethanol yield of 297 L/tonne at 48.9 g/L. Graphical AbstractGraphic table of content.