Abstract: A process for producing levulinic acid and its esters from biomass is disclosed comprising: (i) feed preparation module characterized by subjecting biomass to a high-temperature refining treatment; (ii) hydrolysis reaction module that facilitates the hydrolysis of biomass to its respective sugars and their subsequent transformation to levulinic acid, formic acid, furfural, and char as well as facilitates the separation of lignin-based char by-product; (iii) product separation and recovery module utilizing a solvent extraction technique such as using furfural by-product as extracting solvent; and (iv) optionally, conversion of levulinic acid to levulinate ester. When desired, the disclosed process may be integrated into existing pulp mills.