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•Ethanol production from recycled paper sludge showed to be economically viable.•Integrating cellulases recycling resulted on a superior economic performance.•Solid fraction recovery enabled a superior total ethanol production.•Enzyme recycling is economically viable unless enzyme price decreases at least 34%.
The economics of Recycled Paper Sludge conversion into ethanol was here assessed with emphasis on integrating a cellulase recycling system.
Without cellulases recycling this process presented positive economic outputs (payback period of 7.85 years; 10.90 Million US$ of accumulated NPV) despite the modest ethanol titers. Recycling both free and solid-bound enzymes allowed considerable savings of enzyme but also an increase on annual costs (0.88%), resulting on a superior economic output: payback period decreased to 7.25 years; accumulated NPV increased to 14.44 Million US$. Recycling exclusively the liquid fraction enabled a clear costs reduction, however, also total ethanol decreased, attenuating the abovementioned benefits. Targeting higher ethanol concentrations, superior solids consistencies were also evaluated. Despite a costs reduction, total ethanol decreased due to a higher ethanol retention on the solid. A sensitivity analysis further revealed that the cost of enzymes and ultrafiltration membrane may be critical on enzyme recycling economic feasibility.