In this study, Leptochloa fusca L. Kunth or Kallar grass (KG) was thermochemically (0.625M NaOH solution followed by steam treatment at 121°C for 1 h) pretreated and utilized as a substrate for ethanol production in simultaneous saccharification and fermentation process. A four‐factor, full factorial, rotatable central composite design of response surface methodology was used to develop a statistical model for the optimization of process variables such as substrate concentration, enzyme concentration, temperature, and time. Analysis of variance for ethanol production and the substrate conversion efficiency (SCE) by Kluyveromyces marxianus demonstrated that 10% pretreated KG, 0.6 mg/mL enzyme concentration, 40°C temperature and 48 h of simultaneous saccharification and fermentation time were the optimized variables. At optimum factor setting, predicted values of ethanol production and SCE were 30 g/L and 82%, respectively. The Experimental/validation experiment was in close agreement with the predictive model and the results obtained was 40 g/L and 83.74% for ethanol production and SCE, respectively. © 2017 American Institute of Chemical Engineers Environ Prog, 37: 569–576, 2018