<P><B>Abstract</B></P> <P>Fermentation–pervaporation–catalysis (FPC) integration process was employed to produce bio-butadiene using sweet sorghum juice as feedstock. After <I>in situ</I> ethanol removal from fermentation broth, permeate of pervaporation membrane (478.6 g/L bio-ethanol) was directly converted into butadiene by an Ag/Mg–Si catalyst. A butadiene yield of 64.1% with a butadiene selectivity of 75.8% was achieved within 6 h of operation. The integration process showed a great potential on high final product yield in a long-term operation. Following this protocol, about 16 g of bio-butadiene was produced from 1 kg sweet sorghum stalk. The integration process showed a potential in further application for bio-butadiene and materials production.</P> <P><B>Highlights</B></P> <P> <UL> <LI> Fermentation–pervaporation–catalysis integration process for butadiene production. </LI> <LI> Sweet sorghum juice was used as the substrate. </LI> <LI> 478.6 g/L ethanol was <I>in situ</I> separated and used for butadiene production </LI> <LI> A butadiene yield of 64.1% with a selectivity of 75.8% was achieved. </LI> <LI> About 16 g of butadiene was produced from 1 kg sweet sorghum stalk. </LI> </UL> </P> <P><B>Graphical abstract</B></P> <P>[DISPLAY OMISSION]</P>