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Find out who received a Governor's Awards in each of the seven categories:
Alcoa Inc., Lafayette Operations manages and operates six melting furnaces fueled by natural gas. Each furnace is designed to transfer melted metal through a filter-system, where argon and chlorine are added for fluxing, then poured into a casting pit. Until 2004, the Alcoa Lafayette Operations used a standard unsealed-filter-box, an energy-intensive unit and significant source of air emissions.
Alcoa evaluated the potential for using sealed, in-line filter box, constructed such that virtually no ambient air would enter the headspace above the metal. After three years of research, development and design evaluations, Alcoa Lafayette secured funding and implemented its first inert filter box in 2004. The results have been very positive in regards to energy efficiency, product quality and environmental quality improvements. The team approach has also advanced Alcoa Lafayette's overall EHS system and philosophy at the facility. Benefits of the project have been: improved aluminum quality; reduction of particulate matter; reduction of aluminum dross generation and disposal; improved energy efficiency; and enhanced safety of metal degassing.
Ryobi Die Casting Inc. makes transmission casings for several major automobile manufacturers through an aluminum casting process. Energy intensive reverberatory furnaces melt aluminum in preparation for the die casting process. Since 2000, Ryobi has carried out a series of voluntary furnace upgrades and modifications to reduce energy use and aluminum waste (dross) production. This energy and raw material efficiency project reduces Roybi's natural gas usage by 34,440 million BTU per year (27 percent reduction) and reduced the production of aluminum dross by 759,600 pounds annually. Annual energy and material cost savings of this project amount to nearly $900,000. Ryobi received an Industrial Energy Efficiency Fund loan from the Lieutenant Governor's Energy Group in 2000 to begin this project. Environmental benefits resulting from the project
Utilimaster Corporation manufactures custom walk-in vans and truck bodies for the likes of Federal Express, UPS, Frito-Lay and the U.S. Postal Service. An innovative and energy efficient, microturbine-based, combined heat and power (CHP) system was installed at their truck washing and painting facility. A natural gas-fired microturbine is used to produce electricity. The "waste" heat is utilized in several ways:
The system generates 70 kW of electricity and provides 473,000 btu/hr with an input of 9 therms/hr of natural gas. It was placed in service June of 2004 and has shown improvements in product quality, decreased emissions and reduced energy costs. Previous CHP projects have either incorporated a fluid loop or used direct exhaust to deliver process heat. This system uses heat captured in a fluid loop and redirects the remaining heat from the post-turbine heat exchanger exhaust to a second process, all operator controlled by an integrated control system. This system is Indiana's first CHP application utilizing an Ingersoll-Rand Powerworks microturbine to regenerate a desiccant drying system and was designed with the assistance of NiSource Energy Technologies (NET).
An innovative and energy efficient, microturbine-based, combined heat and power system was installed at the Stripco steel processing plant in Osceola, Indiana with the assistance of NiSource Energy Technologies (NET). Natural gas is used to produce electricity and the "waste" heat is utilized; to heat rolling oil for cold rolled steel processing; supply space heating for the building; and, provide domestic hot water for maintenance cleaning. The system can generate 60kW of electricity and provide 375,000 Btu/hr with an input of 8 therms/hr of natural gas. The system has proven itself to be an environmentally sound combined heat and power project, offering benefits in product quality, waste reduction and health and safety. It has been in service since December of 2002, and since then has generated 837,000 kWh of electricity, delivered 57,000 therms of heat and helped avoid the production of 4.5 tons of NOx that would have been produced by traditional electric generation.
INDOT's Greenfield District has excelled in source reduction and recycling efforts over the past five years as a part of the State's Greening the Government goals. Not only has Greenfield modeled itself on the State's goals of recycling specific materials, such as office paper, cardboard, and aluminum and steel cans, the District has also gone above and beyond those initial goals. The Greenfield District reclaims and recycles materials such as motor oil, oil filters, scrap tires, asphalt and concrete, guardrails and signs, mercury containing devices as well as toner cartridges and electronic waste such as cell phones and pagers.
In addition, the Greenfield District has continuously kept their employees in the "loop" to ensure that they are aware of on-going and developing greening activities and programs, including an award program that recognizes employees for their greening efforts. With new ideas and programs coming on-line each year, continued growth is anticipated in both the short and long-term for Greenfield District source reduction and recycling efforts.
Mossy Point Nature Preserve: Thanks to a multi-partner effort, Parke County has secured its first stand-alone nature preserve, called Mossy Point, a 104 acre woods, located on beautiful Sugar Creek. Securing this property was made possible through a complex collaboration including government (Indiana Heritage Trust (IHT), Indiana Department of Natural Resources (IDNR), non-profits (Central Indiana Land Trust Inc. (CILTI), The Indiana Nature Conservancy (TNC), and private industry (Lilly Clinton Laboratories). The property has several unique aspects, including a rich stand of native hemlock, butternut tree, ¾ mile of creek frontage, rock outcroppings, steep ravines, and is home to bald eagles.
While the natural value of this property was clear to the initiators of the project, the momentum to save this land quickly increased as land use professionals, biologists, and educators confirmed the rare beauty and biological diversity of this unique ecosystem. Each of the acquisition partners contributed through providing financial support and technical assistance in conducting the biological surveys. CILTI will be the owner and enter into a management agreement with Sycamore Trails Resource Conservation and Development Council (STRCD) to provide long-term stewardship. Permanent protection of the Mossy Point Nature Preserve will be provided for through an IDNR conservation easement.
In 2004, out of concern for the community and to emphasize exercise as a path to a healthy life style and longevity, Memorial Hospital constructed River Bluff Trail on 1.3 miles of abandoned railway. The rail line had become a dangerous eyesore, over-run by weeds and brush, trash and broken bottles. Three decaying bridges were in need of renovation.
Located on the north side of the Eel River, the track runs from Michigan Avenue to Davis Road in downtown Logansport. The 10-foot wide paved and landscaped trail is designed for walking, running, biking and roller-blading, with bridge overlooks, resting places and a picnic area. The Trail is handicap assessable and features a one-of-a-kind canoe/kayak launch, especially designed for those with physical disabilities.
Land in the downtown of any city has significant monetary value. However, this land was used to create a greater value--not to an investor--but to the city, county and the surrounding area.
Although developers, builders or manufacturers could have purchased this land, the Trail beautifies the area, offers a free exercise option that helps to improve the health of the community. By identifying and providing a beneficial use for this property, the Hospital remained true to its slogan: "Your Community Resource for Optimal Health."
Franklyn Sechler was instrumental in the planning, development and funding of the 1.5 miles St. Joseph River Greenway. This 8 foot wide concrete/asphalt path was completed in 2004 and has served thousands of community members by providing recreational and educational resources that are not available anywhere else in DeKalb County. The path has benches, birds and bat houses, scenic overlooks, outdoor classrooms, informational signage and wild flowers. Without Mr. Sechler's insight, wisdom and willingness to share his land and funds, this greenway would not have happened. In addition to his participation in the development of the Greenway, Mr. Sechler donated 13.4 acres of prime farm and wood land, adjacent to the greenway, to the public school for use as an educational facility and public park. These contributions by Mr. Sechler are just the tip of the iceberg regarding his community involvement and support.
Improving Kids' Environment (IKE) through innovative secret shopper survey, the non-profit organization helped government and citizens understand that a high percentage of retailers weren't adequately informed to help consumers with home projects involving lead-based paint and pesticides. The secret shopper survey revealed that stores gave customers accurate advice less than 30 percent of the time. The benefits of IKE's outreach have extended beyond Indiana's borders. IKE produced a toolkit for communities to duplicate the survey. The study has received attention from management of national retailers and a national paint manufacturer association and helped state government officials improve the rate of compliance with pesticides regulations.
Over the course of 14 months, the Indiana Recycling Coalition (IRC) developed the E-Scrap Action Program (ESAP). ESAP targets electronics waste (e-scrap) as a major priority, because this waste stream can be hazardous to the environment and costly to manage. The initial phase of the E-Scrap Action Program brought together key stakeholders from across the state to discuss issues and potential solutions regarding the future of e-scrap in Indiana. Stakeholders included 109 entities from the private sectors, Government, non-profits, associations and others.
The project resulted in a series of recommendations on how the state can address the issue of e-scrap from policy, regulatory, legislative and educational perspectives. The project also included the development of the E-Scrap Action Program Toolkit, which can be accessed via IRC's web site.
The Indiana State University Recycling Center began in May 1990, with the intent of reducing the amount of materials sent to landfills. Over the years, the Center's activities have evolved to include an interactive educational component.
The Center now gives recycling tours and presentations, and holds workshops for members of Indiana State University, Terre Haute, and surrounding communities. All educational presentations consist of a brief history of Indiana State University recycling program along with the methods and means for success. The hands-on portion of the presentations generates great interest and fun for kids, as they undertake activities such as: 1) making paper; 2) using glass aggregate to create patio blocks; 3) showing and discussing products made with recycled plastics; 4) planting gardens with seeds embedded in homemade paper; and 5) creating crafts from various recyclable materials. They now share their ideas and programs with over 5,000 Hoosiers annually.
A tour of the facility allows attendees to see the processes and equipment used to gather and prepare recycled items for market. Their drive-through collection area displays proof of community involvement and appreciation by increased participation. The Center works to ensure that the drive through area demonstrates the ease with which recycling can be accomplished so that even small children understand the recycling concept.
Don's DCI Drycleaning has converted its drycleaning operations from a hazardous dry cleaning solvent, called perchloroethylene, to a non-hazardous, environmentally friendly-solvent, by the name of Pure Dry®. Pure Dry® is a special formulation of petroleum products that contains no benzene or other human carcinogens. In addition to being safer than other petroleum-based solvents, Pure Dry® is gentler on garments. In order to use Pure Dry®'s technology, Don's DCI Drycleaning had to invest $225,000 in new equipment. Pure Dry® also costs the company an extra $9.00 per gallon. The company has absorbed this cost without raising prices, with the expectation that customers will appreciate the product's benefits and do more business as a result.
Precoat Metals has updated its chemical coating process by replacing a traditional aqueous treatment system with a gas-fired, infrared oven. The process begins when a chemical coater roll applies a chromic acid solution to metal strips (the solution provides corrosion resistance and improves paint adhesion.) The strips are then dried in the gas-fired, infrared oven. Prior to converting to the gas-fired, infrared oven system, Precoat Metals used an aqueous system, which resulted in the generation of approximately 376,000 gallons of chrome-containing wastewater per year. The new system allows the water, used to clean-up the chemical coater, to be returned to the raw material drum and used again.
National Starch and Chemical (NSC) processes more than 3,920,000 pounds of corn per day. The corn is first soaked (steeped) in an acidic solution of sulfurous acid, which releases the corn starch from the other components (germ, fiber and gluten). The sulfurous acid solution is traditionally made by dissolving liquid sulfur dioxide (SO2) into water. In 2002, NSC used over a million pounds of liquid SO2. Liquid SO2 is an extremely volatile and highly toxic chemical that poses a significant risk to NSC employees, the company, and the local community. During 2003 and 2004, NSC began to replace liquid SO 2with sodium bisulfite (SBS), a safe, non- toxic chemical that NSC demonstrated to be a viable alternative to the corn wet-milling process. NSC has reduced its risk of a hazardous chemical transportation accident and improved worker safety.
In 2004, Reilly Industries, Inc. implemented a project that decreased the amount of benzene used by 80 percent, reduced emissions by 25 percent and improved the energy efficiency in the production process by 200,000 (MMBTU) per year. These energy savings were accomplished by replacing older equipment with newer, more efficient equipment, and by redesigning the manufacturing process to a more continuous operation.
Three young women in Washington High School's DECA - the Distributive Education Clubs of America Workgroup saw an opportunity to increase recycling rates in Washington, Indiana and took the initiative to implement an education, awareness and promotion program. The DECA Workgroup members began by developing a plan and identifying specific target markets that include citizens, schools, and businesses.
They then developed materials and distributed recycling pledges and recycled-content product purchasing policies to local businesses. Local businesses responded at a rate of approximately 20%, taking interest in this opportunity and requesting additional information. The DECA Workgroup members followed-up and even provided on-site waste audits to these businesses.
As a result of the outreach to all sectors of the community, there was a remarkable increase in the amount of materials dropped off at area recycling centers, escalating from 10.5 tons in 2003 to 251 tons in 2004. Through the efforts of these three young women, the City of Washington is not only benefiting environmentally, but also fiscally. The City has saved $375 per month in tipping fees it would normally pay, and also received approximately $10,000 in revenue through the sale of recyclable commodities it has collected. The City responded by thanking the DECA Club and extending a warm invitation for them to continue to lead the community in pursuit of recycling and environmental excellence.
Fairmont Homes, along with its affiliates, are a privately owned business that manufactures homes and recreational vehicles. This manufacturing complex encompasses over 600 acres, with almost two million square feet of manufacturing buildings, providing unique opportunities and challenges in developing an organized recycling program.
The development of a structured recycling process has been achieved through leadership, organization, training, specialized equipment, assigning recycling team leaders in each plant, and maintaining close communication with suppliers.
In 2004, Fairmont Homes started a Recycle Team, which includes assigning a representative from each of their 18 plants. Monthly meetings are held to discuss recycling in each plant. To help maximize their recycling efforts, they purchased a vinyl grinder, a lacquer thinner re-claimer, two Clean Burn waste oil burners and four balers. Additionally, Fairmont Homes has demonstrated a dedication to minimizing its waste streams through source reduction efforts, including working with several vendors to switch to reusable shipping containers and/or returnable containers. In 2004, Fairmont Homes and Gulf Stream Coach recycled over 14,500 tons of materials.
Ferro Corporation has reduced the amount of waste sent to the landfill by implementing waste reduction, and recycling programs. Ferro also implemented pollution prevention programs, and as a result of their environmental efforts, Ferro has increased their efficiency, improved health and safety and has benefited economically. Ferro Corporation has eliminated $596,068 in landfill costs, saved 1.7 million in raw material purchases and realized $66,768 from sale of corrugated cardboard and scrap metal. This is a total saving of more than $2,362,836 since 1988.
The folks at Ferro continually search for methods and opportunities to incorporate post-industrial and post-consumer plastics into their products, using 5.9 million pounds of this material in 2003.
Another economic benefit is realized by reclaiming scraps, including captured dust from the bag house, generated when making finished products. These materials are reground and re-extruded and put back into the manufacturing process.
Through enhancement of existing programs and creation of new programs, Roche Diagnostics increased the volume of recyclables by 71% (compared to 2003) for a total of 913 tons of recyclables. The overall recycling rate was increased from 23% to 43% during 2004 with an estimated cost savings of $383,000. In addition, approximately 250,000 ft 3 of waste was diverted from landfills. Innovative enhancements were made to the cardboard recycling program, increasing its collection volume by 11% and increasing the economic benefits as a result of baling cardboard.
A newly created plastic recycling program yielded 105 tons of recyclable plastic in its first year and continues to grow, as 41 tons of plastic were collected during the first quarter of 2005 (as compared to 27 tons during the same time period of 2004.) In addition to the recycling improvements, several reuse programs have been created. Approximately 15,000 pallets were reused for international shipping, and approximately $136,000 was saved by reusing packaging materials such as ice bricks, layer pads, and corner protectors. The management in the organization, as well as several dedicated employees and Safety & Environmental teams, is key to the successful implementation of the necessary changes to production processes and waste management.
Toyota Motor Manufacturing, Indiana, Inc. (TMMI) has been certified to the ISO 14001 standard by Det Norske Veritas since November 1999. TMMI has utilized the ISO 14001 Environmental Management System (EMS) to minimize the environmental effects of its production processes. Results accomplished through TMMI's EMS include: a 64 percent reduction in VOC emission; 33 percent reduction in hazardous waste generation; 30 percent reduction in energy consumption; and 33 percent reduction in water usage.
In March of 2000, Madison Chemical formally adopted the ISO 14001 standard for EMS. Madison Chemical knows that pollution prevention can pay rich dividends, as they continuously strive to replace regulated materials with non-regulated materials in their formulas. In the past five years, Madison Chemical has: reduced their usage of SARA 313 reportable materials by 42 percent, replaced an average of 50,000 pounds per year of glycol ethers with an advanced surfactant technology; reduced their solid waste generation by 25 percent per pound produced, reduced their electric consumption by 7 percent; switched from being classified as a small quantity generator of hazardous waste to a conditionally exempt small quantity generator, and improved their Material Safety Data Sheet to provide more information about products to both their customers and emergency responders.
Styline's Environmental Management System (EMS) is entrenched into every aspect of its daily operations, with an emphasis both on the facility's performance as well as community leadership. Vendors and staff alike are expected to observe the company's reduced idling policy, which aims to reduce harmful tailpipe emissions. The company is a local leader in anti-idling at schools, and is working with officials, parents and media to raise awareness about reducing harmful tailpipe emissions. Staff at the highest levels of management, employees on the production lines, and the maintenance department is provided with information, tools and resources for superior environmental stewardship through reduced air emissions.