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Agro-waste management processes are evolving through the development of novel experimental approaches to understand the mechanisms in reducing their pollution levels efficiently and economically from industrial effluents. Agro-industrial effluent (AIE) from biorefineries that contain high concentrations of COD and color are discharged into the ecosystem. Thus, the AIE from these biorefineries requires treatment prior to discharge. Therefore, the effectiveness of a continuous flow bioreactor system (CFBS) in the treatment of AIE using hybrid waste sludge biochar (HWSB) was investigated. The use of a bioreactor with hydraulic retention time (HRT) of 1–3 days and AIE concentrations of 10–50% was used in experiments based on a statistical design. AIE concentration and HRT were optimized using response surface methodology (RSM) as the process variables. The performance of CFBS was analyzed in terms of COD and color removal. Findings indicated 76.52% and 66.97% reduction in COD and color, respectively. During biokinetic studies, the modified Stover models were found to be perfectly suited for the observed measurements with R2 values 0.9741 attained for COD. Maximum contaminants elimination was attained at 30% AIE and 2-day HRT. Thus, this study proves that the HWSB made from biomass waste can potentially help preserve nonrenewable resources and promote zero-waste attainment and principles of circular economy.

Apart from protecting the environment from undesired waste impacts, wastewater treatment is a crucial platform for recovery. The exploitation of suitable technology to transform the wastes from pulp and paper industries (PPI) to value-added products is vital from an environmental and socio-economic point of view that will impact everyday life. As the volume and complexity of wastewater increase in a rapidly urbanizing world, the challenge of maintaining efficient wastewater treatment in a cost-effective and environmentally friendly manner must be met. In addition to producing treated water, the wastewater treatment plant (WWTP) has a large amount of paper mill sludge (PMS) daily. Sludge management and disposal are significant problems associated with wastewater treatment plants. Applying the biorefinery concept is necessary for PPI from an environmental point of view and because of the piles of valuables contained therein in the form of waste. This will provide a renewable source for producing valuables and bio-energy and aid in making the overall process more economical and environmentally sustainable. Therefore, it is compulsory to continue inquiry on different applications of wastes, with proper justification of the environmental and economic factors. This review discusses current trends and challenges in wastewater management and the bio-valorization of paper mills. Lignin has been highlighted as a critical component for generating valuables, and its recovery prospects from solid and liquid PPI waste have been suggested. Graphical abstract

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.

The effects of biochar properties on crop growth are little understood. Therefore, biochar was produced from eight feedstocks and pyrolyzed at four temperatures (300°C, 400°C, 500°C, 600°C) using slow pyrolysis. Corn was grown for 46 days in a greenhouse pot trial on a temperate and moderately fertile Alfisol amended with the biochar at application rates of 0.0%, 0.2%, 0.5%, 2.0%, and 7.0% ( w / w ) (equivalent to 0.0, 2.6, 6.5, 26, and 91 t biochar ha −1 ) and full recommended fertilization. Animal manure biochars increased biomass by up to 43% and corn stover biochar by up to 30%, while food waste biochar decreased biomass by up to 92% in relation to similarly fertilized controls (all P  < 0.05). Increasing the pyrolysis temperature from 300°C to 600°C decreased the negative effect of food waste as well as paper sludge biochars. On average, plant growth was the highest with additions of biochar produced at a pyrolysis temperature of 500°C ( P  < 0.05), but feedstock type caused eight times more variation in growth than pyrolysis temperature. Biochar application rates above 2.0% ( w / w ) (equivalent to 26 t ha −1 ) did generally not improve corn growth and rather decreased growth when biochars produced from dairy manure, paper sludge, or food waste were applied. Crop N uptake was 15% greater than the fully fertilized control ( P  < 0.05, average at 300°C) at a biochar application rate of 0.2% but decreased with greater application to 16% below the N uptake of the control at an application rate of 7%. Volatile matter or ash content in biochar did not correlate with crop growth or N uptake ( P  > 0.05), and greater pH had only a weak positive relationship with growth at intermediate application rates. Greater nutrient contents (N, P, K, Mg) improved growth at low application rates of 0.2% and 0.5%, but Na reduced growth at high application rates of 2.0% and 7.0% in the studied fertile Alfisol.

The application of contaminated paper sludge on arable land in southwest Germany caused the occurrence of a broad range of poly- and perfluoroalkyl substances (PFASs) on soil. Recently, the dead-end transformation products (TPs) perfluorooctanoic acid and perfluorooctanesulfonic acid were detected in groundwater and drinking water. The precursors and other transformation products mostly remained unknown. Therefore, HRMS screening by Kendrick mass analysis and assignment of homologous series in combination with suspect screening were applied to identify original PFASs and their TPs in four different soil samples from sites where contaminated paper sludge was applied. In total, twelve compound classes comprising more than 61 PFASs could be fully or tentatively identified. The data reveal that contamination mainly originates from polyfluorinated dialkylated phosphate esters (from 4:2/6:2 to 12:2/14:2), N-ethyl perfluorooctane sulfonamide ethanol–based phosphate diesters (only C8/C8) and transformation products of these precursors. Contamination patterns can be attributed to PFASs used for paper impregnation and can vary slightly from site to site.

High per- and polyfluorinated alkyl substance (PFAS) concentrations have been detected in agricultural soils in Southwest Germany. Discharges of PFAS-contaminated paper sludge and compost are suspected to be the cause of the contamination. Perfluorinated carboxylic acids (PFCAs) have been detected also in groundwater, drinking water, and plants in this area. Recently, previously unknown compounds have been identified by high-resolution mass spectrometry (HRMS). Major contaminants were polyfluorinated dialkylated phosphate esters (diPAPs) and N-ethyl perfluorooctane sulfonamide ethanol–based phosphate diester (diSAmPAP). In this study, HRMS screening for PFAS was applied to 14 soil samples from the contaminated area and 14 impregnated paper samples which were from a similar period than the contamination. The paper samples were characterized by diPAPs (from 4:2/6:2 to 12:2/12:2), fluorotelomer mercapto alkyl phosphates (FTMAPs; 6:2/6:2 to 10:2/10:2), and diSAmPAP. In soil samples, diPAPs and their transformation products (TPs) were the major contaminants, but also FTMAPs, diSAmPAP, and their TPs occurred. The distribution patterns of the carbon chain lengths of the precursor PFAS in soil samples were shown to resemble those in paper samples. This supports the hypothesis that paper sludge is a major source of contamination. The presence of major degradation products like PFCAs, FTSAs, or PFOS and their distribution of carbon chain lengths indicate the activity of biotic or abiotic degradation processes and selective leaching processes from the upper soil horizons.

Cellulosic wastes represent a great environmental challenge, with potential conversion to product-added value through microbial fermentation. Currently, bacterial cellulose (BC) is considered a promising natural polymer for multiple applications. However, the high production cost challenges its wide application. Hence, the current study evaluated the applicability of paper sludge as a cost-effective medium for both cellulases and BC production. The local isolate Streptomyces rochei revealed the highest cellulase production titer (about 3 U/mL) at optimized conditions. For BC production, batch and fed-batch fermentation strategies were evaluated using enzymatically hydrolyzed paper sludge. The results asserted the advantage of fed-batch fermentation for advanced BC production (3.10 g/L) over batch fermentation (1.06 g/L) under the same cultivation conditions. The developed BC membranes were characterized through different instrumental analyses, which revealed an increase in fiber diameters and crystallinity under fed-batch fermentation. Furthermore, BC/magnetite (BC/Fe3O4) nanocomposite was developed by an in-situ approach. The newly developed composite was evaluated for dye removal applications, using methyl orange (MO) as a model. The dye removal conditions were optimized through Box Behnken design (BBD), which indicated maximal MO removal (83.5%) at pH 3.0 and BC/Fe3O4 concentration of 0.1 mg/dL after 60 min. Therefore, the current study asserts the good applicability of enzymatically hydrolyzed paper sludge as a medium for cost-effective BC production and the high capacity of BC/magnetite nanocomposite for MO decolorization. The study paves the way for the cost-effective implementation of BC/magnetite nanocomposite for dye removal.

The pulp and paper industry is a major source of lignocellulose-containing streams. The components of lignocellulose material are lignin, hemicellulose, and cellulose that may be hydrolyzed into their smaller components and used as feedstocks for valorization efforts. Much of this material is contained in underutilized streams and waste products, such as black liquor, pulp and paper sludge, and wastewater. Bacterial fermentation strategies have suitable potential to upgrade lignocellulosic biomass contained in these streams to value-added chemicals. Bacterial conversion allows for a sustainable and economically feasible approach to valorizing these streams, which can bolster and expand applications of the pulp and paper industry. This review discusses the composition of pulp and paper streams, bacterial isolates from process streams that can be used for lignocellulose biotransformations, and technological approaches for improving valorization efforts.Key points• Reviews the conversion of pulp and paper industry waste by bacterial isolates.• Metabolic pathways for the breakdown of lignocellulose components.• Methods for isolating bacteria, determining value-added products, and increasing product yields.

Paper mill sludge (PMS) is featured with a high content of cellulose and hemicellulose, and using its characteristics to make paperboard can achieve a high-value utilization of PMS, which has attracted growing interest. In this study, currently prevalent landfill, incineration technologies (generating heat and electricity by incineration), and three paperboard technologies (medium density fiberboard, pulp board, and corrugated paper) were evaluated and compared via life cycle assessment (LCA) and life cycle costing (LCC) methods. LCA results show that the PMS-to-pulp board outperforms others with an energy conservation and emission reduction (ECER) value of − 2.86 × 10 −8 , while the landfill exhibits the highest overall environmental impact with an ECER value of 4.80 × 10 −9 . LCC results reveal that the PMS-to-pulp board delivers the highest economic profit with $257.357, while the landfill is the lowest with $ − 35.63. The PMS paperboard technologies are more economically friendly than the incineration technologies due to additional electricity/steam consumption during the PMS pre-drying process in incineration. In addition, different scenarios were set up to explore national GHG emission reduction potential by increasing paperboard technologies application rate and reducing the proportion of landfill and incineration. The scenario analysis suggests that replacing 90% of landfill and incineration ratio with PMS paperboard technologies could tremendously improve the overall emission reduction performance with − 9.08 × 10 10 kg CO 2 eq. This result indicates that the PMS treatment technology transformation has a significant favorable impact on the achievement of the “carbon neutrality” target.

Excess sludge in the paper industry is a hazardous solid waste that requires urgent and proper disposal for environmental protection and resource utilization. In this study, a novel magnetic biochar (Fe-SDBC) synthesized from paper sludge through one-step pyrolysis was employed to activate persulfate (PDS) for the efficient removal of acid orange 7 (AO7). The results indicated that Fe-SDBC could effectively activate PDS to remove 97.8% of AO7 within 90 min, with 89.4% removed within 5 min. Fe-SDBC had unique properties with abundant adsorption and active sites, including iron-containing compounds and oxygen-containing functional groups. The addition concentrations of Fe-SDBC (0.5 g/L) and PDS (10 mM) were optimized based on response surface methodology. Furthermore, Fe-SDBC presented good stability over a wide range of pH (3 ~ 11) and reusability in cyclic experiments. Coexisting ions, such as CO 3 2− , HCO 3 − , and PO 4 3− , had an inhibitory effect on AO7 removal. Both radical and non-radical pathways were proved to be involved in the Fe-SDBC/PDS system for AO7 removal, with singlet oxygen ( 1 O 2 ) being the dominant species. Additionally, the degradation pathways were investigated and toxicity assessment was evaluated. This work will provide a potential approach for paper sludge recycling in the wastewater treatment. Graphical Abstract