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

1. “3rd Global Network Conference on Resource Efficient and Cleaner Production” Greening the sugar production value chain at local level MSc.Yaniris Lorenzo Acosta Chief of ICIDCA Focal Point of Cuba NCPN Sugar Agro industry of Cuba Montreux, Switzerland September 4-7 , 2013 ICIDCA

2. Greening the value chain Sugar Enterprise JESUS RABÍ, CALIMETE, MATANZAS, CUBA Main Links • Primary production (sugar cane harvest). • Cultivation and hauling of sugar cane. • Sugar processing (sugar mill). • Revaluation of byproducts from sugar production and waste cycle closing (alcohol, energy, composting, biogas, and effluents ferti-irrigation). • Internal and external commercialization.

3. 1. Primary Production: Sugar cane harvest BEFORE AFTER • Use of chemicalfertilizerstoprovide N, P and K sources. • Use of chemicalpesticidesto control plagues and use of chemicalherbicides. • Successful use of biological and natural products to favor the atmospheric N fixation and the supply of essential microelements. • Use of biological estimulants, nematicides, pesticides, and herbicides. Cultivated area: 9 748 ha/year Yield: 84 ton/ha Harvest season: 160 days

4. Biological products • Herbio BIOCONTROL. • Benefits in sugarcanecultivation • It substitutes the use of chemical herbicides • It controls the weeds and is very effective against: • Marrullero (Ipomoea trifida ) • Frailecillocimarrón (Croton lobatus) • Hierbalechera (Chamaecysehyssopifolia) • Hierbalechosa (Euphorbia heterophylla) • Frijol marrullero (Vignavexillata) • Cebolleta chive (Cyperusrotundus • 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 • 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

5. 2. Cultivation and hauling of sugar cane BEFORE AFTER Technological equipment in bad conditions and inefficient • Harvest machines: 18 • Tractors: 20 • Trucks: 18 Substitution of technological equipment • Harvest machines: 6 • Tractors: 10 • Trucks: 8 BENEFITS: Considerable savings in fuels, spare parts and improvements in work conditions.

6. 3. Sugar Processing: Sugar mill Sugar production capacity: 350 t/d Ground Cane: 3 105 t/d Molasses produced: 105 t/d

7. 3. Sugar Processing: Sugar mill Efficiency measures in the use of resources and the 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.

8. 3. Sugar Processing: Sugar mill 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.

9. 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.

10. REVALUATION OF SOLID WASTES COMPOST PRODUCTION Sludge, Ashes, Bagasse • Compost: process of aerobic decomposition of organic matter by the microorganisms, in a controlled way. • the production of organic fertilizer (compost) is a solution alternative for the use of residuals, to contribute to environment sanitation and the improvement of soils with a consequent positive effect on agricultural yields. • the production of compost uses all the sludge, the ashes and part of the pith generated in the process. • it is directly applied in the fields (10 t/ha) and substitutes chemical fertilizers: N (270 kg,) P2O5 (230 kg) and K2O (70 kg).

11. WASTEWATERS TREATMENT BIOGAS PRODUCTION Vinazzes and effluents of Torula yeast production • 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.

12. REVALUATION OF LIQUID WASTES FERTI-IRRIGATION Industrial Effluents • 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.

13. 5. Internal and external commercialization BEFORE AFTER • Sugar production 35 000 t/year. • 40 % of produced sugar is devoted to exports and the rest for national consumption. • Quality of raw sugar 99 Pol. • Increase of sugar production by availability of raw material: sugar production 42 000 t/year. • Increase of sugar production devoted to exports, 49 %. • Increase in the quality of raw sugar 99,2 Pol.

14. “3rd Global Network Conference on Resource Efficient and Cleaner Production” ICIDCA Focal Point of Cuba NCPN e-mail: yaniris.lorenzo@icidca.edu.cu Telephone: (537) 696 7237 Fax: (537) 698 8243 Address: Vía Blanca No 804 y Carretera Central, San Miguel del Padrón. La Habana, CP 11000. Cuba. www.icidca.cu