Montreux, SwitzerlandSeptember 4-7 , 2013

1

Greening the sugar Greening the sugar production value chain at production value chain at

local level local level

MSc. Yaniris Lorenzo AcostaChief of ICIDCA Focal Point of Cuba NCPNSugar Agro industry of Cuba

Greening the value chain Sugar Enterprise JESUS RABÍ, CALIMETE, MATANZAS, CUBA

1.Primary production (sugar cane harvest).

2.Cultivation and hauling of sugar cane.

3.Sugar processing (sugar mill).

4.Revaluation of byproducts from sugar production and waste cycle closing (alcohol, energy, composting, biogas, and effluents ferti-irrigation).

5.Internal and external commercialization.

Main Links

1. Primary Production: Sugar cane harvest

BEFORE AFTERUse of chemical Use of chemical

fertilizers to provide fertilizers to provide N, P and K sources.N, P and K sources.

Use of chemical Use of chemical pesticides to control pesticides to control plagues and use of plagues and use of chemical herbicides.chemical herbicides.

Successful use of Successful use of biological and natural biological and natural products to favor the products to favor the atmospheric N fixation atmospheric N fixation and the supply of and the supply of essential microelements.essential microelements.

Use of biological Use of biological estimulants, estimulants, nematicides, pesticides, nematicides, pesticides, and herbicides. and herbicides.

Cultivated area: 9 748 ha/yearYield: 84 ton/haHarvest season: 160 days

Bioenraiz BIOFERTILIZER.

•Reduction of 41 kg Urea/ha (inorganic nitrogenated fertilizers by the fixation of

atmosphere nitrogen).•Promotes root-taking, produces fitohormones,

anti-bacteria and antifungicidal compounds.•Improves the physical conditions of the soils

Herbio BIOCONTROL.

Benefits in sugar cane cultivation

•It substitutes the use of chemical herbicides•It controls the weeds and is very effective

against: •Marrullero (Ipomoea trifida )•Frailecillo cimarrón (Croton lobatus) •Hierba lechera (Chamaecyse hyssopifolia) •Hierba lechosa (Euphorbia heterophylla) •Frijol marrullero (Vigna vexillata)•Cebolleta chive (Cyperus rotundus

FitoMas BIOESTIMULANTE.Benefits

•Increase in sugarcane production of 12.3 t/h.

•Diminishes the use of Glifosato herbicide 24%.

•Decrease of other consumables (agrochemicals and combustibles).

•Higher incomes by the increase of yield and quality of the crops.•Soil improvements

Biological products

2. Cultivation and hauling of sugar cane

BEFORE AFTER

Technological equipment in bad conditions and inefficientHarvest machines: 18Tractors: 20Trucks: 18

Substitution of technological equipment Harvest machines: 6Tractors: 10Trucks: 8

BENEFITS: Considerable savings in fuels, spare parts and improvements in work conditions.

3. Sugar Processing: Sugar mill

Sugar production capacity: 350 t/d Sugar production capacity: 350 t/d Ground Cane: 3 105 t/dGround Cane: 3 105 t/dMolasses producedMolasses produced: 105 t/d: 105 t/d

Efficiency measures in the use of resources and the Efficiency measures in the use of resources and the cleaner production (RECP)cleaner production (RECP)

Segregation of wastewaters according to type of pollution.Use of cooling water systems with treated water and closed cycles for efficient water use. Condensate recovery that allows its use as feed water for boilers and technological use. Decrease of waters used for cleaning in process equipment. Removing the sludge in dry and never be diluted.Thermal insulation of equipment and piping.

3. Sugar Processing: Sugar mill

IMPACT OF MEASURES IMPACT OF MEASURES

Construction of wastewater collection system.Decrease of water consumption from 1.05 to 0.42 m3/t of ground cane, water savings: 250 000 m3 of water in the harvest season 2012. Decrease of liquid waste emissions: 200000 m3, harvest season 2012. Reduction of polluting load: 1000 t/COD equivalent.Increase of electricity generation: 3600 MW sold to the national electric system.

3. Sugar Processing: Sugar mill

4. Revaluation of byproducts from sugar production and waste cycle closing.

Alcohol production from molasses. Production of heat and electricity from sugar cane

bagasse.Production of compost from sludge and ashes.Production of biogas from distillery vinasses and

sugar mill wastes.Ferti-irrigation of sugar cane with liquid effluents.

COMPOST PRODUCTIONSludge, Ashes, BagasseCOMPOST PRODUCTIONSludge, Ashes, Bagasse

REVALUATION OF SOLID WASTESREVALUATION OF SOLID WASTES

BIOGAS PRODUCTIONVinazzes and effluents of Torula yeast production

BIOGAS PRODUCTIONVinazzes and effluents of Torula yeast production

WASTEWATERS TREATMENTWASTEWATERS TREATMENT

Anaerobic treatment of slurry with the obtaining of biogas, fertilizer and treated water.

It reduces 70-75 % of the residual organic load.

It reduces the emissions of greenhouse gases (GEI) in 42 000 t CO2 equivalent.

Renewable energy: 15 000 m3 of biogas/day are generated, equivalent to 7,5 t fuel oil.

New employment possibilities are generated, which contributes to local economy sustainability.

Investment: 3700-3800 USD/m3.

FERTI-IRRIGATIONIndustrial EffluentsFERTI-IRRIGATIONIndustrial Effluents

REVALUATION OF LIQUID WASTESREVALUATION OF LIQUID WASTES

Soil enhancer in semi-arid, alkaline zones and with large amounts of calcium and magnesium carbonates and bicarbonates.

ADVANTAGES:

•Increases in production of sugar cane (8 t/ha).

•Improves soil physical conditions.

•Regular amounts of N, P, K, are added as well as S and Fe.

•Improves chemical properties of medium and low fertility soils.

•Increases tenors of micro-nutrients in the soil.

5. Internal and external commercialization

BEFORE AFTERSugar production 35 000 t/year.Sugar production 35 000 t/year.40 % of produced sugar is 40 % of produced sugar is

devoted to exports and the rest devoted to exports and the rest for national consumption.for national consumption.

Quality of raw sugar 99 Pol.Quality of raw sugar 99 Pol.

Increase of sugar production Increase of sugar production by availability of raw by availability of raw material: sugar production material: sugar production 42 000 t/year.42 000 t/year.

Increase of sugar production Increase of sugar production devoted to exports, 49 %.devoted to exports, 49 %.

Increase in the quality of Increase in the quality of raw sugar 99,2 Pol.raw sugar 99,2 Pol.

e-mail: yaniris.lorenzo@icidca.edu.cu

Telephone: (537) 696 7237Fax: (537) 698 8243

Address: Vía Blanca No 804 y Carretera Central, San Miguel del Padrón.

La Habana, CP 11000. Cuba.

www.icidca.cu

“3rd Global Network Conference on Resource Efficient and Cleaner Production”