Valorization of Residual Streams from Pulp and Paper Mills: Pretreatment and Bioconversion of Primary Sludge to Bioethanol

Techno-economic analysis of biomass value-added processing informed by pilot scale de-ashing of paper sludge feedstock

Paper sludge biomass represents an underutilized feedstock rich in pulped and processed cellulose which is currently a waste stream with significant disposal cost to industry for landfilling services. Effective fractionation of the cellulose from paper sludge presents an opportunity to yield cellulose as feedstock for value-added processes. A novel approach to cellulose fractionation is the sidehill screening system, herein studied at the pilot-plant scale. Composition analysis determined ash removal and carbohydrate retention of both sidehill and high-performance benchtop screening systems. Sidehill screening resulted in greater carbohydrates retention relative to benchtop screening (90% vs 66%) and similar ash removal (95% vs 98%). Techno-economic analysis for production of sugar syrup yielded a minimum selling price of $331/metric ton of sugar syrup including disposal savings, significantly less than a commercial sugar syrup without fractionation. Sensitivity analysis showed that screening conditions played a significant role in economic feasibility for cellulosic yield and downstream processes.

Pulp-paper industry sludge waste biorefinery for sustainable energy and value-added products development: A systematic valorization towards waste management

The pulp-paper industry is one of the main industrial sectors that produce massive amounts of residual sludge, constituting an enormous environmental burden for the industries. Traditional sludge management practices, such as landfilling and incineration, are restricted due to mounting environmental pressures, complex regulatory frameworks, land availability, high costs, and public opinion. Valorization of pulp-paper industry sludge (PPS) to produce high-value products is a promising substitute for traditional sludge management practices, promoting their reuse and recycling. Valorization of PPIS for biorefinery beneficiation includes biomethane, biohydrogen, bioethanol, biobutanol, and biodiesel production for renewable energy generation. Additionally, the various thermo-chemical technologies can be utilized to synthesize bio-oil, hydrochar, biochar, adsorbent, and activated carbon, signifying potential for value-added generation. Moreover, PPIS can be recycled as a byproduct by incorporating it into nanocomposites, cardboard, and construction materials development. This paper aims to deliver a comprehensive overview of PPIS management approaches and thermo-chemical technologies utilized for the development of platform chemicals in industry. Substitute uses of PPIS, such as making building materials, developing supercapacitors, and making cardboard, are also discussed. In addition, this article deeply discusses recent developments in biotechnologies for valorizing PPIS to yield an array of valuable products, such as biofuels, lactic acids, cellulose, nanocellulose, and so on. This review serves as a roadmap for future research endeavors in the effective handling of PPIS.

Getting Value from Pulp and Paper Industry Wastes: On the Way to Sustainability and Circular Economy

The pulp and paper industry is recognized as a well-established sector, which throughout its process, generates a vast amount of waste streams with the capacity to be valorized. Typically, these residues are burned for energy purposes, but their use as substrates for biological processes could be a more efficient and sustainable alternative. With this aim, it is essential to identify and characterize each type of waste to determine its biotechnological potential. In this context, this research highlights possible alternatives with lower environmental impact and higher revenues. The bio-based pathway should be a promising alternative for the valorization of pulp and paper industry wastes, in particular for bioproduct production such as bioethanol, polyhydroxyalkanoates (PHA), and biogas. This article focuses on state of the art regarding the identification and characterization of these wastes, their main applied deconstruction technologies and the valorization pathways reported for the production of the abovementioned bioproducts.

Transformation of pulp and paper mill sludge (PPMS) into a glucose-rich hydrolysate using green chemistry: Assessing pretreatment methods for enhanced hydrolysis

Pulp and paper mill sludge is a waste stream derived from the pulp and paper making industry, comprised of organic and inorganic material in the form of cellulose, hemicellulose, lignin and ash. In South Africa, approximately fivefour hundred thousand wet tonnes are produced per annum and is currently disposed via landfilling or incineration. However, these disposal methods raise environmental and financial concerns. This waste stream is an attractive feedstock for fermentable sugars, mainly glucose, recovery and can be redirected for valorisation as a feedstock for microbial fermentation to produce value-added products. Sugar recovery by enzymatic hydrolysis, as opposed to acidic hydrolysis, is a promising approach but is hampered by the lignin and inorganic material found in pulp and paper mill sludge. Several treatment steps to reduce or remove these components prior to enzymatic hydrolysis are assessed in this review. Pretreatment improves hydrolysis of cellulosic fibres and ensures a substantial yield of sugars.

Review on pulp and paper activated sludge pretreatment, inhibitory effects and detoxification strategies for biovalorization

Biovalorization of pulp and paper activated sludge to value-added products could be an effective alternative to traditional sludge management methods, which tend to pose serious environmental issues. Since pulp and paper activated sludge consists of microbial biomass, cellulose, hemicellulose and lignin and thus, could be subjected to different hydrolysis methods to solubilize sludge solids and release simple sugars to form value-added products by the microbial fermentation process. Hence, different sludge hydrolysis methods have been summarized in this review paper. However, hydrolysis of lignocellulosic materials generates variety of toxic compounds during hydrolysis and causes detrimental effects. Therefore, different toxic compounds and their impact on microorganisms, cellulolytic enzymes and fermentation process have been discussed in detail and recent strategies to counteract the problems of inhibitors have also been briefly explained.

Concurrent production of sodium lignosulfonate and ethanol from bagasse spent liquor

This study was done with the aim of lignosulfonate and ethanol production from different spent liquors of bagasse pulping process. For this purpose, alkali lignin from bagasse alkali liquor was separated and was sulfomethylated to produce soda lignosulfonate (SLig). Furthermore, raw bagasse was directly treated with sodium sulfite in acidic and neutral conditions to produce BLig and NLig bagasse lignosulfonate, respectively. In addition, the pentoses and hexoses impurities in lignosulfonates were fermented to ethanol using Candida guilliermondii. Results showed that the molecular weight of NLig lignosulfonate was considerably high comparing to the SLig and BLig lignosulfonates. A high level of thermal resistance was found in case of SLig regarding to the other samples at 500 °C. Fermentation of the spent liquors with Candida guilliermondii led to a maximum ethanol yield of 7.0, 1.0 and 5.1 g L^-1 in NLig, SLig and BLig, respectively.

Second Generation Bioethanol Production: On the Use of Pulp and Paper Industry Wastes as Feedstock

Due to the health and environment impacts of fossil fuels utilization, biofuels have been investigated as a potential alternative renewable source of energy. Bioethanol is currently the most produced biofuel, mainly of first generation, resulting in food-fuel competition. Second generation bioethanol is produced from lignocellulosic biomass, but a costly and difficult pretreatment is required. The pulp and paper industry has the biggest income of biomass for non-food-chain production, and, simultaneously generates a high amount of residues. According to the circular economy model, these residues, rich in monosaccharides, or even in polysaccharides besides lignin, can be utilized as a proper feedstock for second generation bioethanol production. Biorefineries can be integrated in the existing pulp and paper industrial plants by exploiting the high level of technology and also the infrastructures and logistics that are required to fractionate and handle woody biomass. This would contribute to the diversification of products and the increase of profitability of pulp and paper industry with additional environmental benefits. This work reviews the literature supporting the feasibility of producing ethanol from Kraft pulp, spent sulfite liquor, and pulp and paper sludge, presenting and discussing the practical attempt of biorefineries implementation in pulp and paper mills for bioethanol production.

Batch and fed-batch simultaneous saccharification and fermentation of primary sludge from pulp and paper mills

Primary sludge from a Portuguese pulp and paper mill, containing 60% of carbohydrates, and unbleached pulp (as reference material), with 93% of carbohydrates, were used to produce ethanol by simultaneous saccharification and fermentation (SSF). SSF was performed in batch or fed-batch conditions without the need of a pretreatment. Cellic^® CTec2 was the cellulolytic enzymatic complex used and Saccharomyces cerevisiae (baker's yeast or ATCC 26602 strain) or the thermotolerant yeast Kluyveromyces marxianus NCYC 1426 were employed. Primary sludge was successfully converted to ethanol and the best results in SSF efficiency were obtained with S. cerevisiae. An ethanol concentration of 22.7 g L^-1 was produced using a content of 50 g L^-1 of carbohydrates from primary sludge, in batch conditions, with a global conversion yield of 81% and a production rate of 0.94 g L^-1 h^-1. Fed-batch operation enabled higher solids content (total carbohydrate concentration of 200 g L^-1, equivalent to a consistency of 33%) and a reduction of three-quarters of cellulolytic enzyme load, leading to an ethanol concentration of 40.7 g L^-1, although with lower yield and productivity. Xylitol with a concentration up to 7 g L^-1 was also identified as by-product in the primary sludge bioconversion process.

Integrated bioconversion of pulp and paper primary sludge to second generation bioethanol using Saccharomyces cerevisiae ATCC 26602

Primary sludge, from different pulp and paper mills, was used as feedstock in simultaneous saccharification and fermentation (SSF) processes to produce ethanol. SSF was carried out with Saccharomyces cerevisiae ATCC 26602 yeast and NS 22192 enzymatic extract using 150gL(-1) of carbohydrates (CH) from primary sludge. The effect of sterilization, reduction of enzyme dosage and fed-batch vs. batch conditions were studied. The removal of sterilization can be considered since no contamination or atypical by-products were observed, although SSF efficiency slightly decreased. The reduction of the enzyme dosage from 35 to 15FPUgCH(-1) was successful. Despite of initial mixing difficulties, batch SSF enabled higher ethanol concentration (41.7gL(-1)), conversion yield (48.9%) and productivity (0.78gL(-1)h(-1)), compared to the fed-batch process at the same conditions of low enzyme dosage of 5FPUgCH(-1) and high solids content of 21.7%, rarely found in literature.