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Find out who received a Governor's Awards in each of the seven categories:
Aluminum is produced through the electrolytic reduction of aluminum oxide. During the refining process, oxygen is released and can be trapped on the under side of the carbon anodes used to transfer the electric current in the pot. Alcoa's project involves pressing a slot into each anode. The slot provides an escape route for the oxygen from under the anode, which results in lower pot voltage. The lower pot voltage, along with improved pot stability, has reduced power consumption of approximately 0.10 KWH/LB of aluminum produced. Alcoa Warrick Operations produced 594,000,000 pounds of aluminum in 2005. The slotted anode project will result in 59,400 megawatts of annual electricity savings.
NiSource Energy Technologies, Inc., designed a Combined Heat and Power (CHP) system centered on the installation of one 70kW, natural gas-fired Ingersoll-Rand PowerWorks microturbine for electric and thermal load peak shaving. The microturbine generator based CHP system is installed at Manchester Tank in Elkhart, Indiana. The high-efficiency CHP system will be used to reduce plant electrical usage and demand. The exhaust steam is routed directly to a well-ventilated bake oven to assist in meeting base thermal requirements of the tank finishing process. The bake oven is used to cure the powder coat finish on tank product.
Rose Acre is nominated for constructing wetlands at their Seymour plant. The constructed wetlands serve as a pretreatment for plant process effluent prior to final treatment. This wetland also filters and cleanses stormwater, which prior to construction of this wetland, simply flowed from the site naturally.
Save the Dunes Conservation Fund, a respected, established 501(c)(3) non-profit organization, created the Indiana Coastal Restoration Action Team (ICRAT) to coordinate restoration resources in the Lake Michigan coastal region. This partnership between public and private organizations has worked to assess restoration needs, and coordinate and provide training on restoration techniques. The ICRAT restoration project began in October 2004 and has a projected completion date of April 2006. ICRAT has held numerous training events to date and increased the capacity of local land managers to successfully plan and manage the properties they oversee. Furthermore, the ICRAT project will continue to reduce the reliance of local communities on third party contractors, thus lowering the overall cost to manage natural areas in northwest Indiana.
The goal of this project was to reduce emissions by selecting water-based coatings that meet the performance of current VOC-based coating materials. New technology was introduced in Rockwell Automotive's painting and dipping processes to provide improved adhesion and insulating properties. As a result of changing to water-based coatings, Rockwell Automotive reduced VOC emissions from 63.29 tons per year (1994) to 5.45 tons per year (2005). This reduction led to a 91.4% reduction in VOC emissions and a 98% reduction of Hazardous Air Pollutants (HAPs) over the last ten years.
During the production process, Firestone Building Products utilizes sand and granules during the coating process. Unfortunately, this generates a sand and granule waste stream. Typically, recycling projects using similar waste streams have been limited to small percentages being recycled. Firestone's project is unique in that they are able to recycle 100% of this waste. Firestone has deposited this waste stream in the southside Indianapolis landfill on an annual basis since 1990. In 2005, Firestone redirected 100%, or approximately 3,800 tons, of this waste steam from the landfill and used it as a supplement ingredient in an asphalt paving grade mixture. This material is used in non-state work in Indiana for private drives, parking lots, and miscellaneous other projects.
When Maury Hudson took the full time Educator's position with the Dearborn County Solid Waste Management District in January 2004, she readily adopted the District's reuse center as her project. Dubbed Creation Station, Ms. Hudson scavenged three states for suitable shelving, many times in the evenings or on weekends. She beseeched local businesses and county residents for usable materials to fill those shelves and searched for creative ideas to use the collected materials. Then, she had to find someone to combine the materials and the ideas into useful products. It's a continuous circle and Ms. Hudson is constantly engaged in all stages of the process. In its first year open to the public, Creation Station diverted 3,483.7 pounds of materials from the landfill through its 191 participants.
Nappanee Window has developed an innovative program that reuses rout outs (materials leftover when openings are cut in trailers) from manufacturing customers. Nappanee Window takes a significant portion of the material that was previously hauled away to landfills and creates new doors from the recycled materials, and then sells the doors back to their customers at a significantly discounted price. Nappanee Window has partnerships with 18 manufacturing plants to reuse rout outs, which accounts for over 27% of their monthly sales. Through the rout out program, 24.5 tons of waste material - including EPS foam, wood, plastic, fiberglass, and fiberglass resins - are diverted from landfill each month, resulting in large cost savings for participating customers.
The Crane team makes a concerted effort to find ways to recycle or reuse as many of the materials from munitions as possible before subjecting the munitions to open burning or open detonation. From 2004-2005, Team Crane was responsible for the reuse of 200,000 MJU decoy flares with an associated cost savings of $7.06M. Excessive moisture trapped in the item made decoy flare ignition unreliable. Demilitarization cost would have totaled $580,000. A rework would prevent a total unit loss of $5.2M.
The new rework process included disassembly and removal of the defective igniter, installation of a new igniter, drying of the grain assembly and installation into a new case. In late fiscal year 2005, rework begun by private industry and lots were submitted for acceptance in January 2006. The government now has a process to rework 200,000 decoy flares. Team Crane's efforts have resulted in reduced hazardous materials usage (142,555 pounds flare composition and hexane), reduced production costs ($11.30 versus $26.00 per unit), disposal cost savings, and avoided HAP emission (32,000 pounds hexane). The Team Crane project is a great example of how Crane can meet its mission requirements while proving a strong commitment to the environment. Team Crane through education, effort, and planning, will strive to identify and implement source reduction and recycling.
Rolls-Royce Corporation (RRC) has demonstrated significant five year continuous environmental improvements. Since the implementation of the EMS in 2000, there have been numerous measurable benefits for the community, the business, and its employees. In the past five years, RRC has reduced electricity consumption by 13%, water usage by 44%, cold cleaning solvent usage by 54%, and the generation of hazardous waste by 73%. These reductions have resulted in an annual savings of over $2,000.000. RRC continues to maintain its ISO 14001 status, lower its injury and illness rates, and improve its neighborhood relations, all while having a positive impact on the local economy.
In 1998, Subaru of Indiana Automotive, Inc. (SIA), became the first automobile assembly plant to be ISO 14001 certified in North America. SIA's environmental policy is to "Eliminate Environmental Risks of Our Operations," and that efficiency and success will only transpire if responsible stewardship of the environment is present in daily operations. Throughout the last five years (2000-2005), SIA has continually improved its recycling rate of 99% in 2005, decreased waste discharged (lb/unit) by 82%, decreased waste generated (lb/unit) by 33 %, decreased toxic emissions (lb/unit) by 8.2%, reduced electrical consumption by 26%, and reduced natural gas consumption by 40%.
An organized Environmental Management System (EMS) also enabled SIA to become "ZERO-Landfill" in 2004 and maintained "Zero- Landfill" throughout 2005. All of SIA's achievements in reducing waste, toxic emissions, and energy consumption have been accomplished through an established and organized EMS supported by top management.
Since 1999, Toyota Industrial Equipment Manufacturing (TIEM's) Environmental Management System (EMS) has reduced VOC's by 33%, HAP's by 80%, electrical consumption by 24.4%, hazardous waste by 16.8%, and natural gas consumption by 65%. Starting April 1, 2004, TIEM reduced the amount of non-hazardous solid waste going to the landfill by 100% through utilizing a waste to energy facility. In 2004, TIEM sent 969 tons of materials to this facility. TIEM's commitment is to eliminate landfilling of all materials. From 1999 to 2004, TIEM has increased production by 30% and building floor space by 17%; however electrical usage has only increased by 19.5%, water usage by 23%, and natural gas consumption by 6%. Toyota's EMS has produced many positive results, which increases the level of environmental awareness in their customers and suppliers.