This present work compares various pretreatment techniques, single/binary solvent system, biomass drying methods and biomass particle sizes to ascertain effective lipid extraction process for marine trebouxiophycean microalga Chlorella vulgaris BDUG 91771. Of the tested methods, homogenization or direct solvent extraction (DSE) pretreatment, chloroform/methanol binary solvent system, and <= 600 mu m particle size extracted maximum lipid of 22.1% irrespective of different biomass drying methods. Further, considering low energy consumption and industrial feasibility, optimization of DSE process kinetics was performed by central composite design. According to central composite design, high lipid recovery was attained with 2:1 chloroform/methanol ratio, 1:5 dry cell weight/solvent ratio, 65 degrees C temperature, 120 min reaction time, and it was highly validated by regression analysis, coefficient determination, F-value, coefficient variation, desirability ratio of the models. It is noteworthy that, the optimized DSE process was compatible with another trebouxiophycean alga Picochlorum sp. BDUG 91281 through biological and technical replicates. In a bioenergy outlook, fuel properties of C vulgaris BDUG 91771 biodiesel such as degree of unsaturation (69.03), long chain saturation factor (2.49), cold filter plugging point (-9.75 degrees C), cloud point (8.1 degrees C), pour point (0.66 degrees C), saponification value (248.2 mg KOH/g), acid value (0.51 mg KOH/g), ash content (0.019%), insoluble impurities (0.022 g/kg) and viscosity (4.1 cSt) comply ASTM D6751, EN 14214 and ISO 15607 standards. (C) 2017 Elsevier Ltd. All rights reserved.