An advanced approach towards sustainable paper industries through simultaneous recovery of energy and trapped water from paper sludge.

This study considered the possibility of reducing the environmental footprint of paper and pulp industry by producing bioenergy from paper sludge by using process wastewater instead of fresh water, and reclaiming water trapped in paper sludge. Experimental studies are conducted with streams from three different pulp and paper mills (virgin pulp mill (VP), corrugated recycling mill (CR), tissue printed recycling mill (TPR)) for sequential bioethanol and biogas production with simultaneous reclamation of water from paper sludge (PS). Total energy yields of 9215, 6387, 5278 MJ/tonne dry PS for VP, CR and TPR, respectively, were obtained for ethanol-biogas production. Virgin pulp paper sludge gave the highest yield for ethanol and biogas in stand-alone processes (275.4 kg and 67.7 kg per ton dry PS respectively) and also highest energy conversion efficiency (55%) in sequential process compared with CR and TPR. Energy and environmental case study conducted on virgin pulp mill has proven the possibility of using paper sludge bioenergy to reduce energy demand by 10%, while reclaiming 82% of the water from the PS, reducing greenhouse gas emissions (GHG) by 3 times and producing solids suitable for land spreading. Integration of a sequential bioprocessing technology into the pulp and paper industry treats wastewater, produces bioenergy and eliminates the need to landfill paper sludge. [Display omitted] • Process wastewater substituted clean water in fermentation and anaerobic digestion. • Sequential bioprocessing reclaimed 65%−85% of entrapped water from paper sludge. • 80% of GHG emissions from landfills is avoided in paper sludge bioprocessing. • Integration of paper sludge bioprocessing in pulp mills can reduce energy demand by 10%. [ABSTRACT FROM AUTHOR]