Water-Based Pretreatment Combined with Severity-Optimized Organosolv Enables Near-Complete Enzymatic Hydrolysis of Wheat Straw at Reduced Energy Demand

Wheat straw is an abundant agricultural residue with high potential for carbohydrate-based bioconversion, yet its efficient utilization is limited by lignocellulosic recalcitrance. This study systematically investigated Organosolv extraction of German wheat straw with the goal of achieving near-complete enzymatic hydrolysis at minimized process severity and energy demand. Process severity was evaluated using the P-Factor concept. In preliminary screening, acid catalysts and liquor ratios were assessed. Strong acids clearly outperformed weak acids: at comparable severity, 5% (w/w, DM) H2SO4 or p-toluenesulfonic acid (PTSA) yielded glucose yields of 83 ± 2.4% and 81 ± 6.2%, respectively, whereas weak acids (phosphoric, lactic, acetic) and a catalyst-free control resulted in only ~20–41% glucose yield. Liquor ratio strongly affected extraction performance; a ratio of 1:19 provided the highest glucose yield (85 ± 1.4%) and robust mixing compared to 1:12–1:15 (67–68%). Two novel pretreatment strategies applied prior to Organosolv extraction, namely hot-water pretreatment (HWP) and water pretreatment (WP), significantly increased hydrolysability compared to untreated straw (58 ± 3%), reaching 79 ± 2% for HWP and 86 ± 5% for WP. DOE-based experiments (135–170 °C; P-Factor 3.0–4.0) showed that increasing temperature from 135 to 150 °C markedly improved hydrolysability (e.g., WP: 74 ± 3% to 96 ± 3%), while further increase to 170 °C provided no additional benefit. Response-surface modeling predicted a maximum hydrolysability of approximately 88% for HWP but complete hydrolysis for WP within 152–170 °C, indicating a broad operational window. Overall, combining simple pretreatment with severity-optimized Organosolv extraction enables energy-efficient, near-complete enzymatic hydrolysis of wheat straw.