Proceedings of the International Society of Sugar Cane Technologists, volume 29, 294-303, 2016

Managing sugar-mill liquid effluent to zero discharge - a

case study of Mehran Sugar Mills Limited

Sanaullah1, Sharif Khan2 and Maren Mogalle3

1Mehran Sugar Mills Limited, Pakistan; hamna_sana4u@yahoo.com
2MirpurkhasSugar Mills Limited, Pakistan
3IPRO, Germany

Abstract Sugar mill liquid effluents containing high levels of pollutants are a threat to our environment. In Pakistan,
although there are stringent rules and regulations for control of effluents, very few mills are currently addressing these
issues. Mehran Sugar Mills Limited (MSM) started a campaign of reducing the quantity of its liquid effluents and their
pollutant parameters. An initial study and water balance of the factory showed that water contained in the cane is sufficient
for all processes and, indeed, provides a surplus. A comprehensive plan over 3 years was prepared in 2013 to replace all
canal water used in the factory with cane water. Several strategies of water conservation, such as elimination, re-use and
recycle, were adopted. IPRO (Germany) were engaged to evaluate the plan. After 3years, MSM is now using only cane
water for its processing. The only effluent generated is spray pond water and the municipal effluent of factory bathrooms
and kitchen area. The surplus cane water is used to dilute the mill effluent. In 2013, when the Effluent Management Plan
(EMP) started, the average effluent was 6116 m³/day and COD levels were about 3000 mg/kg. These have now been
reduced to 1081 m³/day and 1845 mg/kg, respectively, an overall reduction in COD loading of about 89%. The cost of
effluent treatment plant (ETP) for 6116 m³/day effluent was about USD 1.70 million, and this cost has been reduced to
USD 0.6 million for the reduced effluent. MSM has planned to install an ETP by 2016 for the reduced effluent flow to meet
National Environmental Quality Standards (NEQS) for liquid effluent. This paper details the success story of MSM for
combating liquid effluents. Sugar mills are environment friendly industries, unless we pollute the environment. Good
manufacturing practices and managing cane water are the prerequisites of a successful EMP.

Key words Effluent, COD, effluent management plan, condensate, canal water

INTRODUCTION

Mehran Sugar Mills Limited (MSM) is situated in southern Pakistan. Its cane crushing capacity is 11,500 tonnes of cane
per day (tcd) (season 2015-16). Like other mills of the area, effluent loadings were high with flows of 6120 m³/day with
3000 mg/kg chemical oxygen demand (COD) for 10,000 tcd capacity (season 2012-13).At the same time, the mills were
drawing about 5560 m³/day of canal water for mill operations. Usually when the disposal of polluted effluent is not an issue
or management is less concerned about the adverse environmental effects of discharging highly polluted effluent, effluent
levels are high due to negligence. The management of MSM realized the adverse effect of generating polluting effluents
and, considering its corporate social responsibility, decided to reduce the effluent flow and COD levels to meet the National
Environmental Quality Standards (NEQS). As a logical strategy, it was decided to reduce effluent flow and COD levels to
the minimum by improving manufacturing practices and other innovative solutions before installing any effluent treatment
plant (ETP). The cost of an ETP for the base case effluent flow and pollutant concentration was about USD 1.7 million.
The base case effluent data are given in Table 1.

Table 1. Factory raw-effluent data for the base case (2012-13) and after implementation of the Environmental Management
Plan in 2015-16.

Factory raw effluent data NEQS Factory raw effluent data

Pollutant Unit (after EMP) (2015-16)
(Base case) (2012-13) standard
Effluent discharge flow m³/h 255 - 52
Chemical oxygen demand (COD) mg/L 2980 ≤150 1845
Biological oxygen demand (BOD) mg/L 1100 ≤80 710
Oil and grease mg/L 50 ≤10 20
Total suspended solids mg/L 1375 ≤200 167
pH - 5-8 6-9 6.5

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Because the cane supply comprised more than 70% water and less than this was required for mill operations, we developed
the idea to replace canal water with cane water for all of the sugar-manufacturing processes. A team was formed consisting
of members from the mechanical, electrical, instrument, health, safety and environment, laboratory and management
departments headed by the Process Manager. The team prepared a detailed Effluent Management Plan (EMP) for
reducing the effluent flow and its pollutant concentration. Given that expenditure needed to be utilized for other important
projects, the EMP was phased in over three seasons. The object was to reduce effluent flow to a minimum value of 1000
m³/day with less than 1000 mg/kg COD, to reduce the cost of the ETP, and to meet NEQS standards. An additional object
of the EMP was to simultaneously reduce canal water requirements for the mill. All projects were initiated relative to their
impact on effluent flow and pollutant concentration.

METHODOLOGY

Effluent flow reduction

Sugar cane is a unique crop in that it brings all the elements required for sugar manufacturing along with the sugar,
including fiber for energy production and water required for processing. Ideally, there is no need for additional water if cane
water is utilized properly. Considering this, a water balance of the plant was developed for all the inflows and outflows. The
basic equation of the factory water balance was:

Water In = Water out

Water In = Water in Cane + Water from other sources (canal/ground water)

Water Out = Water out from factory through product, by-product, evaporation and effluent

Water circulation in the factory processes, such as condensate usage at mills for imbibition, for processing, for molasses
dilution and for boilers as feed water, has less impact on effluent generation than draining cane water into drains and
utilising canal water for processing. Increased internal circulation of water decreases the plant steam energy efficiency and
thus increases the plant steam requirement, but reduces effluent generation, as surplus condensates are reduced. It is not
economically wise to decrease the plant steam energy efficiency just to reduce effluents.

The following methodology was adopted for reducing the effluent flow:
1- A water balance of the plant was carried out.
2- A list of water consuming and draining points was prepared. This was important to know the sources of canal water
usage and water draining to effluent.
3- A list of all the municipal/sewage water points, including bathrooms, toilets and kitchen waters of the factory, was
prepared for separate disposal to the nearby town’s municipal drain.
4- The philosophy of 5 Rs (Refuse, Reduce, Reuse, Repurpose and Recycle) was adopted for conservation of effluent.

Pollutant loading reduction

Sugar and fine bagasse constitute a major portion of the COD loading in sugar mill effluents. Usually pump leakages,
entrainment from evaporators and pans and overflows of juice or sugar-containing material from storage tanks are the
sources of COD in effluent. Oil leaking from equipment usually finds its way into effluent if not properly managed. The
following methodology was adopted for reducing COD, suspended solids and oil and grease loadings in the effluents:
1- Juice drainage from pumps to be stopped by good equipment maintenance. Juice mixing with effluent to be
prevented by all means.
2- The entrainment catching system for evaporators and pans was analyzed for improvement.
3- Data was collected for storage tank overflow incidents for the last three seasons for appropriate automation to avoid
such overflows.
4- Open drain channels of all houses to be covered to reduce concentrations of suspended solids in effluents.
5- Oil leakage from equipment to be reduced by improved maintenance. Oil mixing with effluent to be prevented by all
means.
6- The ideology that if sugar mills are perfectly designed, maintained and operated with good manufacturing practices,
they do not produce any pollutants in effluents was adopted for reducing COD levels in effluent.

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IMPLEMENTATION

Effluent flow reduction

We conducted a factory water balance. Table 2 describes all the water flows data of the factory for the base-case season
of 2012-13.

Table 2. Cane water balance of the plant at 10,000 tonnes of cane per day (2012-13).

Water In Water Out

Source Quantity (t) Source Quantity (t) % Cane
Evaporation through spray pond 2,732 42.87
Water in bagasse 1,588 24.92
Evaporation from boilers and gas scrubber 1,000 15.69
Water in boiler ash 100 1.57
Water in filter cake 195 3.06
Evaporation from juice flash tank 149 2.34
Evaporation from boiler blow-down 115 1.80
Evaporation through steam leakage 112 1.76
Cane 6,927 Evaporation through soda boiling 100 1.57
Evaporation at mills 100 1.57
Evaporation through NCG Steam 82 1.29
Evaporation from molasses storage tank 50 0.78
Water in molasses 17 0.27
Evaporation from sugar dryer 16 0.25
Evaporation through vertical crystallizer cooling tower 16 0.25
Sugar 1 0.02
Total 6373 100
Canal/Ground Water 5,562 Effluent Water* 6116
Total Water In 12,489 Total Water Out 12,489
*Factory municipal effluent is included.

The factory water balance showed that there was only 554 m³/day (6927-6373=554) surplus cane water, whereas effluent
generation was about 6116 m³/day. This indicated inefficient utilization of cane water and unwanted use of canal water for
process or drainage of water in effluent. The canal water intake quantity was calculated to be 5562 m³/day.

A list of water-consuming areas with their water sources was prepared to quantify and identify water consumption and its
source. If canal water is used for process the condensate will be in surplus by the same amount. This list also identified
the areas of water draining to effluent. Appendix1 describes all the water consumption and effluent generation areas and
the future use of the output flow.

Municipal water is usually discharged to the main factory effluent stream. A list of all the factory municipal water generation
areas was prepared with the objective to redirect the disposal of this effluent to the nearby town’s municipal drain. The
quantity of this municipal water was about 25-50 m³/day and COD in the range of 1000 to 1500 mg/kg.

The water balance of the factory showed that the amount of water carried into the factory through cane exceeds the amount
of water that exits from the factory through products, by-products and vapors. Ideally, only surplus cane water should be
the part of effluent. Furthermore, to maintain the required sanitation standards, washing of house floors is required and
this surplus cane water could be used there. Condensate water, which is cane water (if no canal water is used in process),
could be efficiently utilized for process operations. The following innovative solutions have been successfully implemented
at MSM for problematic areas to replace canal water:

 Mills imbibition water. After heat recovery of process condensate water (through condensate juice heater) it was
used for mill imbibition. The temperature of this condensate was reduced to 65°C, which is considered ideal for
mill imbibition. Canal water used for imbibition was replaced with cane water.

 Boiler blowdown water. This water, which is high in solids and could not be used for processing, was sprayed
onto dry fly ash from the mechanical ash collectors of the boilers. The quantity of blowdown water was reduced

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by improving process condensate quality. Suitable de-entrainment devices were installed at the evaporators to
improve the condensate quality.

 All the surplus condensates were cooled at a cooling tower and this cooled condensate was used for following
applications:
o All the process chemicals were prepared using this condensate, replacing canal water usage.
o Canal water used for sealing water of Nash vacuum pumps was replaced with cold condensate. This
water, after the Nash pump, was collected and pumped to mill house for imbibition.
o Tube cleaning of all the evaporators, pans and juice heater was done with cold condensate. This scale-
containing water is reused in the boiler flue gas-scrubbing system as makeup water. The scale is then
removed from boiler scrubbing system along with boiler ash. These residues were disposed of into cane
fields along with mill mud as a fertilizer.

 Vacuum filter cascade condenser water. Previously, canal water was used for this condenser and drained to the
main drain. It was replaced with spray pond water and recycled.

 Shell testing of vessels. Previously, shell testing of all the vessels was done with canal water and drained to the
main drain. This was replaced with spray pond water and recycled. These vessels were then rinsed with hot
condensate and also drained to the spray pond.

 All the unwanted water taps of the process house were plugged, as they were sources of effluents.

 Caustic soda solution used for evaporator chemical cleaning was reused. Exhausted soda solution was then
collected in a neutralization tank where it was neutralized with acid solution that had been used for first-effect
chemical cleaning. This neutralized salt solution was drained to the effluent.

 Water addition to various magmas in the raw and refining houses was replaced with clear juice and fine liquor.

Pollutant load reduction

The best way for reducing pollutant concentration was to plug the source. Where it was not possible to collect the pollutant
materials (usually process material), it was collected in sumps and reprocessed at appropriate stages of the process.

Juice drainage to effluent. Good equipment maintenance reduced juice leakages. Juice collection sumps were provided at
all the juice, liquor and molasses pumping stations. The collected material was pumped to the defecated juice tank, where
it was heated to 105°C before sending it to the juice clarifier. To maintain good sanitation conditions in the sumps, a biocide
(sodium dithiocabamate) was used after hot water cleaning of the sumps; this was carried out daily.

De-entrainment devices of evaporators and pans were modified to centrifugal vane type separators. This modification
reduced the contamination of juice in condensate and contamination of spray pond water.

Data was collected for storage tank overflow incidents. Automation was provided at the clear and defecated juice tanks
with local level display for operators. These eliminated tank overflows.

All the open channels of house main drains were covered to prevent mixing of suspended solids, especially bagasse which
spreads due to its open storage.

Oil spillage to effluent. Good equipment maintenance significantly reduced oil leakages. An oil skimmer was installed at
the main effluent stream of the mill house to collect any oil contamination in effluents.

Cost of EMP

The total cost incurred for implementation of the EMP was USD 300,000.

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RESULTS AND DISCUSSION

It took 3 years to complete the project of EMP, resulting in the 2015-16 data in Table 1.Figure 1 shows the gradual progress
of effluent flow reduction for the three seasons of EMP. Figure 2 shows the gradual reduction of canal water intake to the
factory for three seasons of EMP.

Flow (m³/day)
4500 4040
4000
3367 3197
3500 2967 Season
2828 2816
3000 2013-14
2500 2002 2160
2000 1743 2014-15
1406 1439 1423 1551
1326 1180
1500
2015-16
1000 1364 1382 1240
500 955 1049 870
675
0
1 2 3 4 5 6 7 8
Fortnight

Fig. 1.Average effluent flows each 2 weeks over three seasons.

Flow (m³/day)
3500 3095
2836
3000 2635 2607
Season
2500 2124 2146
2013-14
2000 1745 1664
1397 1471
1500 1236 2014-15
1530 1597
1000 1381 1433
1109 1186
1037 2015-16
500
0
1 2 3 4 5 6 7 8
Fortnight

Fig. 2. Average canal water intake each 2 weeks over three seasons.

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Figure 3 shows the average annual effluent and intake water flow comparison of the base case season 2012-13 with each
of the three seasons of EMP.

m³/day
7000
2012-13
6000
2012-13
5000

4000

3000 6116 2013-14

5562 2013-14
2000 2014-15
2834 2014-15 2015-16 2412
2015-16
1000
1505 1081 1665
1320
0
Effluent Flow Canal water intake

Fig. 3. Average annual effluent flow and canal water intake.

The results of the implementation of the EMP over the three years can be summarized as:

 Effluent flow was reduced from 6116 m³/day to 1,081 m 3/day. A reduction of 82.3% was achieved against the
target of 83.7%.

 COD loading was reduced by 88% against the target of 95%.

 All other pollutant parameters were reduced significantly.

 The cost of the proposed ETP was reduced from USD 1.7 million to USD 0.6 million, due to the reduction in
effluent flow and pollutant loadings.

 The factory is planning to install an ETP by 2016 to meet NEQS standards.

 Canal water was reduced from 5562 m³/day to 1190 m³/day, or over the 105 days of mill operation 460,000
m³/year. This saved canal water is now available for the inhabitants at the tail end of this canal. In Pakistan
where per capita water availability is less than 1000 m³, the quantity of this saved water is sufficient for a
village of 450 inhabitants.

DISCUSSION

Mills achieved the targets to a great extent. Effluent flow was reduced by 82% against a target of 84%, and COD load
reductions were 89% against a target of 95%.

Although we could not achieve NEQS standards due to higher-than-target COD, BOD and oil and grease levels, we were
able to achieve our target of reducing effluent flow and pollutant concentrations and reducing the cost of the proposed
ETP. The major source of effluent and pollutant is the overflow of spray pond water. This water becomes heavily polluted
due to the exhaustive recirculation and entrainment from the pans. If a factory has enough water to pass through the pans
and evaporator condenser only once, then the pollutant overflow of spray pond could be avoided. Fortunately, our factory
is located very adjacent to an irrigation water canal and we are trying to convince the local authority to allow a one pass of

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canal water from the condenser, i.e. pumping water from the canal for a single passage through the condensers and
discharging it back into the canal. If this is allowed, then not only power for spray pond water could be saved but also about
30% of the cane water from condensed vapors would be available for irrigation. For 1.0 Mt cane crushing, this cane water
comes to 300,000 t of water annually.

CONCLUSIONS

Sugar mills, which are typically considered to be a source of heavy effluents, can significantly reduce the effluent flow to a
reasonably low limit by improved manufacturing practices and innovative solutions, suitable for their own operating
conditions. Preparation and then implementation of an effluent management plan is the key for success. Any reduction of
effluent saves clean canal water by the same amount, which then becomes then available for other useful purposes.

ACKNOWLEDGEMENTS

We are grateful to the management of Mehran Sugar Mills Limited for their support in initiating the effluent management
plan. We thank the staff of MSM for their untiring efforts and valued input for the innovative solutions that led this effort to
successes, and to the IPRO Germany for endorsement of the EMP.

APPENDIX 1

Water consumption and effluent generation areas with recommendations for its next use.

Existing water
Existing disposal Recommended source
House/Equipment source (canal or Recommended disposal
method of water
condensate)
Evaporator tube cleaning Surplus condensate to
Canal water Main drain To be collected separately
water be used after cooling
and re-used at FARS as
Raw and refinery pan Surplus condensate to
Canal water Main drain make-up water.
tube cleaning water be used after cooling
Spray channel overflow To be treated through ETP
Canal water Main drain
drain water and uses as irrigation water.
Canal water to be replaced
V. filter cascade Spray pond water to be
Canal water Main drain with spray pond water and
condenser water used
recycled.
Nash pumps bearing Surplus condensate to To be collected and pumped
Canal water Main drain
cooling water be used after cooling to mills for imbibition.
Already recycled
Power house turbine Service water Already recycled through
Canal water through service water
cooling water circulation tank service water tank.
tank.
Good housekeeping to
Good housekeeping to be
be improved for
Condensate and improved for reducing
T.B Mill floor washing Main drain reducing cleaning
canal water cleaning frequency. Only hot
frequency. Only hot
condensate to be used.
condensate to be used.
T.B fibrizer bearing To be collected and recycled
Canal water Main drain Canal water
cooling water through service water tank.
Good housekeeping to
Good housekeeping to be
be improved for
Raw juice pumps floor Condensate and improved for reducing
Main drain reducing cleaning
washing canal water cleaning frequency. Only hot
frequency. Only hot
condensate to be used.
condensate to be used.
Mechanical float valve or
50 % Condensate
T.B imbibation tank Hot Condensate after electronic auto control to be
and 50 % canal Main drain
overflow heating juice to be used. provided to stop tank
water
overflow.

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Good housekeeping to
Good housekeeping to be
be improved for
Condensate and improved for reducing
T.A Platform washing Main drain reducing cleaning
canal water cleaning frequency. Only hot
frequency. Only hot
condensate to be used.
condensate to be used.
M.Turbine bearing Main drain/service
Canal water
cooling water water tank Discharge to main drain to
Mill Max Drive side Main drain/service be stopped and 100 %
Canal water Canal water
bearing cooling water water tank recycle of water to be
Mill Max bearing cooling Main drain/service ensured.
Canal water
water water tank
Canal water to be replaced
Mill Max, nozzle plate
Canal water Mixed with juice Screened juice with screened mixed juice as
washing water.
per original design.
Mill Max gear bearing To be collected and recycled
Canal water Main drain Canal water
cooling water through service water tank.
Discharge to main drain to
T.B. Mill bearing cooling Main drain/service be stopped and 100 %
Canal water Canal water
water water tank recycle of water to be
ensured.
T.A Fibrizer bearing To be collected and recycled
Canal water Main drain. Canal water
cooling water through service water tank.
Mechanical float valve or
T.A imbibition tank Condensate + Hot condensate after electronic auto control to be
Main drain.
overflow canal water heating juice to be used. provided to stop tank
overflow.
T.A Mill gear bearing Already recycled through
Canal water Service water tank Canal water
cooling water service water tank.
Discharge to main drain to
T.A. Mill bearing cooling Main drain/service be stopped and 100 %
Canal water Canal water
water water tank recycle of water to be
ensured.
Boiler ID and Sec: Fan
Canal water Main drain
bearing cooling water
Feed pump No.1bearing To be collected and recycled
Canal water Main drain Canal water
cooling water through service water tank.
Feed pump bearing
Canal water Main drain
cooling water
Canal water use as Boiler blowdown water
Carried along with
sprinkler water for boiler Canal water to be used for spraying Carried along with ash
ash
ash. on ash.
Boiler feed water sample
Condensate water Main drain - To be closed after sample.
point
This blowdown to be
reduced by improved feed
Boiler No.1, 2, 3, 4 and
water quality.
5Continuous blow down Condensate water Main drain -
As it contains high TDS, it
water
should be used as sprinkler
water for ash.
Laboratory Waste
To be discharged in
Laboratory bathroom Canal water Main drain. Canal water separate approved municipal
drain.
All the sample material
Laboratory analysis Sugar containing should be collected
Main drain. -
water basins water. separately and recycled at
defecated juice tank.
Laboratory condensate It should be diverted to spray
Condensate Main drain. -
sample water pond.
Ground water
Tech: Mosque bathroom Ground water Main drain
To be collected separately
Tech: Mosque floor
Ground water Main drain - and discharged in separate
washing
approved municipal drain.
Workshop hand wash Ground water Main drain

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Condensate / Hot Water

To be collected in under
vacuum condensate tank of
Vapor line juice heater Condensate Main drain
evaporators and used for
process.
Emergency drain in main
Exhaust and vapor
Condensate Main drain drain, no effect on pollutant
condensate tank drain
concentration.
This should be used at A-
Massecuite re-heater
Condensate Main drain sugar remelter as it is near
calorifier drain
to this utility.
Simple automation can stop
this overflow and this highly
Feed water storage tanks
Condensate Main drain pure water could be used for
Overflow
heating of juice and
imbibition purpose.
Process house hot water Overflow to be drained in
Condensate Main drain
tank overflow spray pond

Gestion des effluents liquides de sucrerie pour éliminer tous les rejets - une étude aux Mehran
Sugar Mills Limited

Résumé. Les effluents liquides contenant des niveaux élevés de polluants constituent une menace pour notre environnement. Au
Pakistan, bien qu’il existe des règles strictes et des règlements pour le contrôle des effluents, très peu d’usines se penchent sur ces
questions. Mehran Sugar Mills Limited (MSM) a lancé une campagne pour réduire la quantité de ses effluents liquides et de leur potentiel
de pollution. Une étude initiale et un suivi des eaux de l’usine ont montré que l’eau contenue dans la canne est suffisante pour tous le
processus et, donne même un surplus. Un plan global de plus de 3 ans a été préparé en 2013 pour remplacer toute eau de canal utilisée
dans l’usine par l’eau de la canne. Plusieurs stratégies de conservation d’eau, telles que l’élimination des pertes, la réutilisation et le
recyclage ont été adoptées. IPRO (Allemagne) ont été engagés pour évaluer le plan. Après 3 ans, MSM utilise désormais uniquement de
l’eau de la canne pour son traitement. Le seul effluent généré est celui des bassins à jets d’eau et les effluents des salles de bains et
cuisines. L’eau excédentaire de canne est utilisée pour diluer l’effluent de l’usine. En 2013, lorsque le plan de gestion des effluents (EMP)
a commencé, le volume des effluents était 6116 m³/jour et le COD était 3 000 mg/kg. Ces valeurs sont maintenant réduites à 1081 m³/jour
et 1845 mg/kg, respectivement, une réduction globale d’environ 89 % du chargement COD. Le traitement des effluents (ETP) pour 6116
m³/jour coûtait environ 1,7 millions de dollars (USD), et ce coût a été ramené à 0,6 millions pour l’effluent réduit. MSM a prévu d’installer
un ETP en 2016 pour le control de l’effluent réduit afin de répondre aux normes de qualité environnementale nationale (NEQS) pour les
effluents liquides. Ce document présente en détail le succès obtenu par MSM pour combattre les effluents liquides. Les sucreries sont
des industries qui protègent l’environnement, mais souvent nous polluions l’environnement. Les bonnes pratiques de fabrication et de
gestion des eaux de la canne sont les conditions préalables à un ETP réussi.

Mots-clés: Effluent, COD, plan de gestion des effluents, condensat, eau de canal

El manejo de los efluentes líquidos de la fábrica de azúcar hasta cero descarga - un estudio de caso
de la Mehran Sugar Mills Limited

Resumen. Los efluentes líquidos de las fábricas de azúcar conteniendo altos niveles de contaminantes son una amenaza para nuestro
entorno en Pakistán, a pesar de las reglas limitantes y las regulaciones para el control de los efluentes, muy pocas fábricas de azúcar
atienden sistemáticamente este asunto. Mehran Sugar Mills Limited (MSM) inició una campaña de reducción de la cantidad de efluentes
líquidos y de sus parámetros contaminantes. Un estudio inicial y un balance de aguas en la fábrica mostró que el agua contenida en la
caña es suficiente para todos los procesos e inclusive provee un exceso. Se preparó un plan coherente para tres años en el 2013 para
sustituir toda el agua de canal utilizada en la fábrica por agua de la caña. Se vincularon y adoptaron varias estrategias de conservación
de agua, como eliminación, re-uso, recirculación. La IPRO (Alemania) se vincularon para evaluar el Plan. Después de tres años, MSM
está empleando solamente agua de la caña en su procesos. El único efluente generado es el agua del enfriadero (spray pond) y los
efluentes municipales de los sanitarios y la cocina. El agua excedente de la caña se utiliza para diluir los efluentes de la fábrica en el
2013 cuando el Plan de Manejo de los Efluentes (EMP en inglés) comenzó, el promedio de volumen de efluentes era 6116 m3 / día y los
niveles de COD alcanzaban los 3000 mg/kg. Estos se han reducido a 1081 m 3 /día y 1845 mg/kg respectivamente, que significa una
reducción total de la carga de COD de aproximadamente 89%. El costo de la planta de tratamiento de efluentes (ETP en inglés) para
6116 m3 /día era de aproximadamente USD 1.70 millones y el costo se ha reducido a USD 0.6 millones para los efluentes actuales. La
MSM planea instalar en el 2016, una planta de tratamiento (ETP) para el volumen reducido de los efluentes, que satisfaga los estándares

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nacionales de calidad ambiental (NEOS en inglés) de sus efluentes líquidos. El trabajo que se presenta detalla la exitosa historia de MSM
en el combate a los efluentes líquidos. Las fábricas de azúcar son industrias eco-amigables, excepto cuando contaminamos el entorno.
Buenas prácticas manufactureras y el manejo del agua de la caña son el pre-requisito del éxito de un Plan de Manejo de Efluentes (EMP
en inglés).

Palabras clave: Efluentes COD, plan de manejo de efluentes, condensados, agua de canal

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