Integrated biorefinery approach to utilization of pulp and paper mill sludge for value-added products.

The objective of this work was to examine opportunities for reducing the overall cost of lignocellulose hydrolysis to fermentable sugars. Primary sludge (PS), a negative cost lignocellulosic feedstock, was hydrolyzed sludge using a commercial cellulase preparation (Cellic® CTec2) in presence of non-ionic surfactants. Polyethylene glycol (PEG) 4000 facilitated the highest hydrolysis yield of 74.4% which represented a 2-fold increase over the control without surfactant. Response surface methodological analysis at four variables (hydrolysis time, solids, enzyme, and surfactant loadings) revealed that enzymatic hydrolysis was significantly enhanced by the interactive effect of all factors with solids and enzyme loadings as the most significant parameters (p < 0.05). Using ultrafiltration, 40% of the cellulase enzyme was recovered from the enzymatic hydrolysate and reused on fresh PS substrate. The hydrolysate fermentabilty was evaluated in production of 9.7 g/L bioethanol at 92% ethanol yield using Saccharomyces cerevisiae , and in production of 37.8% biolipids by the oleaginous yeast Cutaneotrichosporon oleaginosum at a carbon to nitrogen ratio of 40. The compression load of a sample prepared from the unhydrolyzed PS solids was 102% higher than Portland cement. The potential for valorization of the unhydrolyzed solids as reinforcement material warrants further investigations. • Enzymatic hydrolysis of primary sludge was optimized using statistical methods. • Surfactants increased the enzymatic hydrolysis efficiency and yield. • About a third of the enzyme activity was recovered and recycled. • Enzymatic hydrolysate was evaluated in bioethanol and biolipid production. • Unhydrolyzed solids from sludge hydrolysis was assesses as reinforcement material. [ABSTRACT FROM AUTHOR]