For the first time, a synergistic energy-efficient combination of microwave-xenon (MW-XE) irradiations in presence of photoactive ternary acidic deep eutectic solvents (TADES) has been applied for intensification of ethyl levulinate synthesis from delignified sugarcane bagasse (DSB) under mild (90 min, 90 °C) and environmentally benign process conditions. The Taguchi orthogonal designed optimized conditions (20 W/cm3 of MW specific irradiation power input, 1 mol/mol of FeCl3 to citric acid ratio, 90 min of reaction time, 150 W of XE specific power input) rendered maximum 61.3 mol% of EL yield (selectivity: 87.70 \(\pm\) 0.5%). Remarkably, synergistic effect of MW and XE irradiation significantly enhanced the EL yield (61.3 mol%) compared to the individual MW (34.52 mol%) and XE (22.67 mol%) irradiation at otherwise optimized reaction conditions. Moreover, the MWXE irradiated reactor (MWXER) exhibited a significant 79.10% increase in EL yield compared to the conventional thermal reactor (CTR), at the expense of 10% less energy consumption. The ethyl levulinate could be recovered efficiently through green protocol from reaction mix resulting in high purity (97 \(\pm\) 0.5%) and TADES was sustainably reused in the process. The optimally generated product EL when blended (5 and 10 vol.%) with B10 and B20 (10% and 20% biodiesel-diesel blend) could provide 21–31% reduction in HC and 7.3–36% reduction in CO in comparison with petro-diesel. It was also explored that, at similar optimal parametric combinations, the TADES produced 29.5% greater EL yield in comparison with the standard ionic liquid BMIMCl. The life cycle environmental impact analysis (LCEIA) of the overall process revealed that the 5 vol.% EL blending with B10 contributed lowest environmental impacts mitigating marine ecotoxicity, human toxicity, fossil depletion, and climate change by 77.9%, 77.4%, 78.4% and 77.5%, respectively.
