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Valorization of Textile Cotton Waste and Textile Sludge into High-Quality Torrefied Biofuel Pellets: Fuel Characteristics and Optimization.

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Title: Valorization of Textile Cotton Waste and Textile Sludge into High-Quality Torrefied Biofuel Pellets: Fuel Characteristics and Optimization.
Authors: Ansari, Irfan1 (AUTHOR) hameed.memon@hamdard.edu.pk, Zaidi, Asad A.2 (AUTHOR), Memon, Abdul Hameed3 (AUTHOR), Hussain, Ahmad4 (AUTHOR), Haleem, Asad Bilal5 (AUTHOR)
Source: Energies (19961073). Mar2026, Vol. 19 Issue 6, p1401. 34p.
Subject Terms: *Pelletizing, *Process optimization, *Biomass energy, *Waste management, *Cotton, *Industrial wastes, *Textile waste
Abstract: This study investigates the conversion of textile wastewater sludge (TWS) and textile cotton waste (TCW) into solid biofuels through pelletization and torrefaction, addressing the growing need for sustainable waste management and alternative fuels in the textile sector. Blended feedstocks were conditioned to ~10% moisture, pelletized into 8 mm cylinders, and thermally upgraded at 200–240 °C for 30–90 min. Proximate and ultimate analyses, calorific value measurements, compressive strength testing, bulk and true density assessment, and TGA–DTG were used to evaluate fuel properties, while response surface methodology (RSM) optimized torrefaction parameters. The TCW-rich 20:80 (TWS:TCW) blend with 5% starch exhibited the most favorable overall performance, achieving a calorific value of 3377 kcal kg−1, ash of 10.3%, bulk density of 554 kg m−3, and maximum compressive strength of 14.9 N mm−2. Torrefaction at 200 °C for 60 min increased the GCV to 4083 kcal kg−1 with a high mass yield of 92%, indicating mild thermal decomposition and good energy retention. Further Torrefaction at 220–240 °C increased GCV to 4362–4565 kcal kg−1, accompanied by expected mass-yield reductions due to increased devolatilization. TGA–DTG confirmed faster and cleaner decomposition for TCW-rich pellets and higher residues for sludge-rich blends. RSM indicated temperature as the dominant factor governing mass and energy yields. These findings demonstrate that optimized co-pelletization and mild-to-moderate torrefaction can effectively transform textile residues into energy-dense, mechanically stable biofuels suitable for industrial heat applications. [ABSTRACT FROM AUTHOR]
Database: Energy & Power Source
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Header DbId: enr
DbLabel: Energy & Power Source
An: 192592575
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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Items – Name: Title
  Label: Title
  Group: Ti
  Data: Valorization of Textile Cotton Waste and Textile Sludge into High-Quality Torrefied Biofuel Pellets: Fuel Characteristics and Optimization.
– Name: Author
  Label: Authors
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  Data: <searchLink fieldCode="AR" term="%22Ansari%2C+Irfan%22">Ansari, Irfan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> hameed.memon@hamdard.edu.pk</i><br /><searchLink fieldCode="AR" term="%22Zaidi%2C+Asad+A%2E%22">Zaidi, Asad A.</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Memon%2C+Abdul+Hameed%22">Memon, Abdul Hameed</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Hussain%2C+Ahmad%22">Hussain, Ahmad</searchLink><relatesTo>4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Haleem%2C+Asad+Bilal%22">Haleem, Asad Bilal</searchLink><relatesTo>5</relatesTo> (AUTHOR)
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  Label: Source
  Group: Src
  Data: <searchLink fieldCode="JN" term="%22Energies+%2819961073%29%22">Energies (19961073)</searchLink>. Mar2026, Vol. 19 Issue 6, p1401. 34p.
– Name: Subject
  Label: Subject Terms
  Group: Su
  Data: *<searchLink fieldCode="DE" term="%22Pelletizing%22">Pelletizing</searchLink><br />*<searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br />*<searchLink fieldCode="DE" term="%22Biomass+energy%22">Biomass energy</searchLink><br />*<searchLink fieldCode="DE" term="%22Waste+management%22">Waste management</searchLink><br />*<searchLink fieldCode="DE" term="%22Cotton%22">Cotton</searchLink><br />*<searchLink fieldCode="DE" term="%22Industrial+wastes%22">Industrial wastes</searchLink><br />*<searchLink fieldCode="DE" term="%22Textile+waste%22">Textile waste</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: This study investigates the conversion of textile wastewater sludge (TWS) and textile cotton waste (TCW) into solid biofuels through pelletization and torrefaction, addressing the growing need for sustainable waste management and alternative fuels in the textile sector. Blended feedstocks were conditioned to ~10% moisture, pelletized into 8 mm cylinders, and thermally upgraded at 200–240 °C for 30–90 min. Proximate and ultimate analyses, calorific value measurements, compressive strength testing, bulk and true density assessment, and TGA–DTG were used to evaluate fuel properties, while response surface methodology (RSM) optimized torrefaction parameters. The TCW-rich 20:80 (TWS:TCW) blend with 5% starch exhibited the most favorable overall performance, achieving a calorific value of 3377 kcal kg−1, ash of 10.3%, bulk density of 554 kg m−3, and maximum compressive strength of 14.9 N mm−2. Torrefaction at 200 °C for 60 min increased the GCV to 4083 kcal kg−1 with a high mass yield of 92%, indicating mild thermal decomposition and good energy retention. Further Torrefaction at 220–240 °C increased GCV to 4362–4565 kcal kg−1, accompanied by expected mass-yield reductions due to increased devolatilization. TGA–DTG confirmed faster and cleaner decomposition for TCW-rich pellets and higher residues for sludge-rich blends. RSM indicated temperature as the dominant factor governing mass and energy yields. These findings demonstrate that optimized co-pelletization and mild-to-moderate torrefaction can effectively transform textile residues into energy-dense, mechanically stable biofuels suitable for industrial heat applications. [ABSTRACT FROM AUTHOR]
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RecordInfo BibRecord:
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    Identifiers:
      – Type: doi
        Value: 10.3390/en19061401
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 34
        StartPage: 1401
    Subjects:
      – SubjectFull: Pelletizing
        Type: general
      – SubjectFull: Process optimization
        Type: general
      – SubjectFull: Biomass energy
        Type: general
      – SubjectFull: Waste management
        Type: general
      – SubjectFull: Cotton
        Type: general
      – SubjectFull: Industrial wastes
        Type: general
      – SubjectFull: Textile waste
        Type: general
    Titles:
      – TitleFull: Valorization of Textile Cotton Waste and Textile Sludge into High-Quality Torrefied Biofuel Pellets: Fuel Characteristics and Optimization.
        Type: main
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      – PersonEntity:
          Name:
            NameFull: Ansari, Irfan
      – PersonEntity:
          Name:
            NameFull: Zaidi, Asad A.
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            NameFull: Memon, Abdul Hameed
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            NameFull: Hussain, Ahmad
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            NameFull: Haleem, Asad Bilal
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            – D: 15
              M: 03
              Text: Mar2026
              Type: published
              Y: 2026
          Identifiers:
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              Value: 19961073
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              Value: 19
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              Value: 6
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            – TitleFull: Energies (19961073)
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