Clean Air Excellence Awards
Past Award Recipients
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Clean Air Technology Award Recipients
Diversey Incorporated Renew Air Scrubber Technology
ReNew® Air Scrubber technology is a pollution control program designed to reduce emissions of unwanted volatile organic compounds from rendering plants. It is an enzymatic technology that works in the rendering facility’s existing wet air scrubber systems, but replaces harsher air scrubber treatments. Conventional systems are based on oxidizers such as sodium hypochlorite, chlorine dioxide, chlorine gas, and ozone, frequently used in combination with strong mineral acids such as sulfuric acid and or hydrochloric acid.
In addition to reducing worker exposure to hazardous chemicals, ReNew® uses significantly less water than other conventional treatments, requires no off-line operations because it does not produce EPA-regulated pollutants in effluent water and delivers air quality that is equal to or better than conventional systems. These product advantages provide facility operators with a lower total cost in use than conventional treatments while reducing the facility’s environmental impact.
Since its commercialization in late 2007, ReNew® Air Scrubber has resulted in the conservation of more than 54.5 million gallons of water at U.S. rendering facilities and has removed over 5 million pounds of oxidizers and mineral acids from commerce, with subsequent reductions in freight-related carbon dioxide emissions.
Genset Ultra-Low Emitting Locomotive
Union Pacific Railroad Company
Union Pacific pioneered the technology behind the ultra-low emitting Genset locomotive, led the development of Genset, and funded construction of the prototype. Today, every major U.S. railroad utilizes Gensets. With a fleet of 165, Union Pacific owns more than half the Gensets in use across the railroad industry. The Genset significantly surpasses US EPA Tier 2 locomotive standards without using special fuels or exhaust after treatment. Rarely do large transportation equipment end users, including airlines, trucking companies or railroads, develop or produce new engine designs, relying instead on commercial manufacturers. However, Union Pacific saw the need for switching locomotives that could reduce diesel engine exhaust emissions. A switching locomotive is one which moves rail cars inside freight yards and between local industries. Switchers do not move freight trains across the country, a task reserved for high-horsepower, longhaul locomotives. Union Pacific was unable to find a locomotive manufacturer that would produce a prototype Genset locomotive, and consequently developed and funded the construction of the first one in 2004. The Genset can perform the same work as a conventional switcher by using multiple smaller, lower-emitting, high-speed diesel engines instead of a single large, medium-speed conventional locomotive diesel engine. The difference is the Genset reduces NOx and PM emissions by 80-90 percent, fuel consumption by 16-40 percent, and greenhouse gas emissions by an equivalent amount. The third generation Gensets will be placed into service later this year.
LNG Port Truck Project
California Cartage Company, LLC
California Cartage Company developed the Liquefied Natural Gas (LNG) Port Project in response to growing concerns over emissions from high-polluting diesel trucks servicing the Ports of Long Beach and Los Angeles. The project has developed an innovative lease-to-own program to ensure that the $32,000 federal tax credit for the natural gas trucks could be captured and passed along to owner-operators who would not have otherwise qualified for the credit. The fuel project has enabled 400 owner-operators to purchase LNG trucks in the largest single deployment of LNG trucks in the U.S., and the first commercial deployment of class-8 heavy-duty trucks meeting U.S. EPA 2010 emission standards. The project has developed important financing models, established LNG as a viable option for heavy-duty trucking operations; and spurred the proliferation of factory-built LNG truck technologies. The net truck payments on these LNG trucks are nearly 50 percent less than new diesel trucks, making them a financially viable alternative. The project has measurably reduced emissions within the heavily impacted and disadvantaged port communities. The trucks annually replace 1.95 million gallons of diesel with domestically-produced LNG, resulting in an annual reduction of 13.9 tons of GHG per truck. Additionally, toxic particulate matter emissions have been eliminated and smog-forming NOx emissions have been reduced by 83 percent.
The E-Pod — Clean Air Systems
In 2008, CleanAIR Systems introduced a new emissions control technology, the E-POD, with the successful installation of seven units on diesel engines powering drill rigs operating in Wyoming's Pinedale Anticline Project Area. It offers more than a 90% reduction of NOx and 85% particulate reduction. It also reduces hydrocarbons and carbon monoxide. It enables a Tier 4 final compliance for Tier 1 and Tier 2 diesel stationary engines, and some Tier 0 engines. It is the only integrated product of its kind currently available that enables this. The E-POD also allows New Source Performance Standards (NSPS) compliance for lean-burning natural gas engines. The E-PODs were installed on seven diesel generators between September 2008 and January 2009, and onsite emissions testing show NOx reductions of 95%. Its unique design allows the E-POD to be transported along with the generator, without the added expense or hassle that are typical of other selective catalytic reduction (SCR) systems.
The Road to Hydrogen — Sunline Transit Agency
SunLine Transit Agency was the first transit agency to own and operate a hydrogen generation and dispensing station. Located in Coachella Valley, California, the station is part of Governor Schwarzenegger's proposed California Hydrogen Highway. The transit agency operates five generations of hydrogen buses that utilize the fuel station, but also wanted to make the fuel available for commercial use. With the support of state and federal agencies, SunLine upgraded the hydrogen station to include both a dedicated hydrogen bus hose and a commercial third party card reader system, allowing the public and outside fleets to purchase hydrogen 24 hours a day. SunLine received its "first in the nation" Hydrogen Hybrid Internal Combustion New Flyer bus in December 2004 and received a hydrogen fuel cell bus the next year. Their new generation of Advanced Technogology Fuel Cell buses will be delivered to the agency in November 2009. The hydrogen buses in SunLine’s fleet have logged over 174,000 miles to date.
Railpower Hybrid Rubber Tire Gantry Crane — RJ Corman RailPower
The Eco-crane product is the first hybrid Rubber Tire Gantry (RTG) crane and the only battery assisted hybrid cranes that are installed in North America. RTGs are cranes used to lift and move shipping containers within a port facility. The system can be installed on new equipment or retrofitted on old systems. The installation of the Eco-Crane (hybrid- battery/diesel power plants) has been completed on three Rubber Tire Gantry (RTG) cranes at Vanterm and Delta Port in the Port of Vancouver. The system demonstrated 70% fuel reduction measured in operation and an emission reduction between 65% and 80%, depending on the crane. They are now installing a new prototype Eco-Crane design for DC motor RTG applications in the Long Beach container terminal. Also, the company has signed a contract with an OEM of cranes used in rail yards. Now, they are in the process to be installed on the first hybrid crane that will be used in a rail yard.
HearthCat Fire Place Technology — Clear Skies Unlimited Inc.
Clear Skies Unlimited Inc. is a small business specializing in innovative catalytic solutions for the most challenging air quality problems. Clear Skies has successfully developed and tested a wood burning fireplace emission control retrofit technology that has the potential to reduce emissions in wood burning fireplaces by as much as 70 to 90 percent in some cases. The HearthCAT™ System Reduces PM2.5 from one modular masonry fireplace to 2.9 g/kg, well below the EPA voluntary program Phase 2 emissions level of 5.1 g/kg. The HearthCAT™-equipped Isokern Fireplace is the cleanest burning open hearth fireplace currently qualified under EPA’s voluntary program. The HearthCAT™ has also been successfully tested and qualified in a factory-built fireplace. The technology has application potential in millions of fireplaces nationwide, since it can be used in new or retrofit fireplaces, and in both open hearth masonry and low mass fireplaces. The HearthCAT™ is a passive catalytic device that employs a smoke capture hood to isolate and destroy the offensive pollutants and wood smoke. The system is easily installed, requires little or no maintenance, and is affordable to the consumer. For four consecutive years, Hearth & Home Magazine had issued the Vesta Challenge to hearth product manufacturers for the creation of a wood burning fireplace retrofit technology that would dramatically reduce particulate emissions without creating any smoke spillage or adversely affecting indoor air quality. In March of 2009, Clear Skies Unlimited won this prestigious award.
Caterpillar D7E with Electric Drive — Caterpillar Inc., Peoria Ill.
Designed completely from the ground up, the Caterpillar D7E is a revolutionary track-type tractor that incorporates more than 100 patents and focuses on maximizing efficiency. Fuel consumption has been reduced by 10 to 30 percent (depending on work load/cycle) and dozing efficiency increased by 25 percent (cubic yards moved/gallon of fuel) compared to previous models. This machine also uses fewer parts and fluids during its useful life. Together, these changes significantly reduce CO2 and gaseous emissions.
The most significant innovation behind this leap forward in technology is a very compact AC electric drive train. This drive train replaces the power shift transmission that is typically used in this size track-type tractor. The technological challenges for electric drive trains in track-type tractors include frequent directional shifts, the need to have very powerful electrical components in a small amount of space (power density), the need to operate in mud and partially submerged in water, as well as making these components work under strong vibration levels.
The innovation of the D7E electric drive train is centered on AC electric technology controlled
by solid-state semiconductors. This continuously variable speed, brushless motor design, combined with sealed and liquid-cooled components are the key breakthroughs that make this technology viable in a track-type tractor.
By overcoming the challenges involved with the designing of the D7E, Caterpillar has opened the door to new applications for electric drives in construction equipment. Now workers on jobsites across the Unites States can look forward to higher productivity and fewer emissions.
Kenworth Green Power Solutions — Kenworth Truck Company, Renton, Wash.
Kenworth Truck Company is committed to providing a broad range of products for the commercial vehicle market that minimize environmental impact through reduced emissions, greenhouse gases, and fuel consumption. This effort is epitomized by three products released in
2008: Kenworth’s Clean Power System, Medium Duty Hybrid, and Natural Gas Powered Vehicle.
The Kenworth Clean Power System is a no-idle, battery-powered system that provides 10 hours of continuous operation during mandatory rest periods for truck drivers. The system is comprised of enhanced insulation, cooling storage capacity for air conditioning, auxiliary heat, high efficiency LED lighting, and 110 volt AC outlets. By eliminating idling during rest periods, the system reduces fuel use by one gallon per hour.
The Kenworth Medium Duty Hybrid Truck is powered by a parallel diesel-electric system. This system, developed in partnership with the Eaton Corporation, also utilizes braking energy to recharge its batteries in preparation for vehicle acceleration. Fuel consumption can be decreased up to 1,500 gallons per year and CO2 by 38 percent for specific applications. The utility configuration can run a hydraulic boom directly from the hybrid batteries, resulting in even greater savings.
The Kenworth Natural Gas Powered Vehicle was developed in partnership with Westport Innovations. This truck uses a small injection of diesel to ignite the high pressure natural gas, which gives the performance and longevity equivalent to a diesel engine, while using domestically available fuel. Fuel is stored as liquid natural gas (LNG) for increased energy density. The factory-built Kenworth T800 LNG truck reduces emissions for NOx by 27 percent, particulate matter by 40 percent, and CO2 by 24 percent.
LEHR Eco Trimmer — LEHR Inc., Los Angeles, Calif.
LEHR Incorporated has developed the LEHR Eco Trimmer, the first hand-held garden tool fueled by propane. The benefits of this fuel have previously only been available for vehicles, forklifts, and large equipment over 12 horsepower. LEHR’s new technology addresses the need for the clean air benefits of propane in the handheld and portable power tool market.
The Environmental Protection Agency (EPA) has identified that emissions from gas-powered grounds keeping equipment are a significant source of air pollution. Compared to gasoline combustion, propane combustion produces 97 percent less particulates, 96 percent less carcinogens and less CO, hydrocarbons, and NOx. In addition, it has zero ozone depleting potential. According to tests conducted by an EPA approved laboratory, the Eco Trimmer surpasses the 2011 exhaust emissions standards for hydrocarbons by over 65 percent and carbon monoxide by nearly 75 percent.
Using the standard 16.4 ounce propane canister as its fuel source, the Eco Trimmer eliminates the possibility of spillage and leakage. The sealed fuel system results in zero evaporative emissions, which is the most difficult to control source of emissions in this product category. This reduces smog-producing pollution created each season by fumes associated with filling/spilling gasoline into lawn products and from fumes escaping from gas cans. Through the use of propane fuel, LEHR has created a cost effective way to help consumers reduce dangerous emissions and their associated health risks.
“miniHybrid” Thermal Systems for Municipal Transit Buses — Tri-County Transportation District of Oregon, Portland, Ore. — Engineered Machined Products, Escanaba, Mich.
The Tri-County Metropolitan Transportation District of Oregon (TriMet) has partnered with Engineered Machined Products, Inc. (EMP) to develop EMP’s “miniHybrid” Thermal Systems for use in municipal transit buses to improve fuel efficiency and reduce emissions. TriMet approached EMP with the idea of using their technology in the transit sector in 2006. TriMet’s Bus Maintenance Department and EMP have worked together to develop and improve the concept of electrifying the cooling system on transit fleets throughout North America.
The thermal system replaces the bus’s hydraulic fan with efficient, controllable electric fans and replaces the standard alternator with EMP’s advanced, high-efficiency Power 450, reducing the horsepower (hp) required from 45 hp to 10 hp. The system also uses reversible fans to clean debris from the radiator to further improve engine efficiency. The technology reduces maintenance and improves safety by eliminating the use of hydraulic fluid. Transit authorities have experienced fuel economy improvements up to 10 percent, depending on location and use, which directly reduces the emissions associated with exhaust from diesel and compressed natural gas (CNG) buses.
The technology can cost effectively retrofit existing buses for $15,000 or be installed at the time of production for $7,500. EMP‘s miniHybrid thermal system fits all existing transit bus drive train technologies, including hybrid and compressed natural gas, allowing universal application in new and retrofitted buses. The opportunity to retrofit fleets with a cost effective technology offers the promise of accelerating emission reductions throughout the transit sector. The potential savings is substantial; transit fleets currently consume over 1.3 billion gallons of gasoline equivalent annually.
Renewable Biogas Fuel Cell Project — City of Tulare Public Works Department, Tulare, Calif.
The City of Tulare, in California’s San Joaquin Valley, is committed to the adoption of clean air technology. The city shows this commitment with their Renewable Biogas Fuel Cell Project that uses digester gas from the city‘s wastewater treatment plant for cogeneration of electricity, while maintaining a nearly zero emission standard. The project was designed and constructed by Alliance Power Inc. of Littleton, Colorado and consists of three Fuel Cell Energy 300 kW DCF300MA biogas fuel cells preceded by a biogas treatment system designed by Applied Filter Technology.
Each of the three fuel cells in the plant generates approximately 300 kilowatts (kW), which together equate to approximately $2,500 worth of electricity per day. In addition to generating electricity with little to no emissions, the fuel cells give use to digester gas that was previously burned in a flare. The fuel cells serve as an energy source for the wastewater treatment facility. Fuel cells release 99 percent less NOx, 99 percent less SOx, and 99.98 percent less PM10 than conventional methods of cogeneration. This project is even more important in the San Joaquin Valley, which is an extreme non-attainment air basin where there is an excessive number of hospitalizations due to air pollution related diseases. Tulare anticipates the addition of a fourth fuel cell to further reduce emissions from its facility.
VOC Elimination Project — Garlock Sealing Technologies, Palmyra, N.Y.
Garlock Sealing Technologies embarked on a project to eliminate the use of an Environmental Protection Agency regulated volatile organic compound (VOC), or hazardous air pollutant (HAP), solvent from the manufacture of its sheet gasket products. This project has promoted a better factory work environment and improved environmental stewardship at its Palmyra, New York facility, and involved changing a process that has been virtually the same since 1905.
Sheet gasket products are manufactured by compressing mixtures of fibers and solvated rubber, resulting in the release of over 100 tons of VOC/HAP emissions per year. During the five-year, $3 million project, many solvent substitutes were investigated and a non-VOC/HAP solvent was found, tried, and proved, resulting in the development of a new manufacturing process. The project included high-efficiency recovery systems to capture and reuse the new non-VOC solvent. The system has realized an average efficiency of 95 percent year-to-date.
The project also resulted in a gasket product with better branding for accurate identification, non-stick properties for easy removal, and most notably a gasket that seals 20 percent better. A better sealing gasket further extends the positive result of VOC/HAP emission elimination. Sheet gaskets are used to seal many thousands of flange joints present in the pipe lines of a typical oil refining, chemical, pulp and paper, or power plant. A better seal means lower fugitive emissions from the flange joints of these and other industrial processing facilities. In November 2007, Garlock’s Palmyra, New York facility made its last VOC/HAP based sheet gasket, resulting in the production of a better product with significantly lower environmental impact.
Renaissance Rumford 1,000 — Renaissance Fireplaces, Bellevue, Wash.
Renaissance Fireplaces has produced the world’s first certified clean burning open fireplace.
First introduced to the fireplace industry at the Hearth Patio and BBQ Association trade show in February 2008, the Renaissance Rumford 1,000 has been specifically developed to surpass the low emissions performance requirements of the new ASTM low mass fireplace standard. It incorporates a positive sealing outside air intake, a gasketed guillotine style glass door, and utilizes an insulated chimney to prevent uncontrolled cold air leakage from the chimney system. In addition to surpassing the national standards for woodstove emissions, the Renaissance Rumford fireplace surpasses the most stringent state standard of 4.5 g/hr set by the State of Washington.
Independent certification testing shows that with the door open emissions were 70 percent less than a typical fireplace, but with the door closed reductions were even more significant with 93 percent less emissions (surpassing EPA Phase 2 standards). Within two minutes of lighting a fire there is no visible smoke exiting the chimney, even with the door open. This technology enables the Renaissance Rumford to burn cleanly and heat large rooms.
Delivering a clean burning fireplace with these performance capabilities is extremely important to the future of wood burning and the environment. Renaissance Fireplaces offers the modern homeowner the ability to burn wood in an environmentally friendly manner.
Foss Hybrid Tugboat — Foss Maritime Company
Foss Maritime Company began constructing a hybrid tugboat in August of 2007, which will be delivered to San Pedro Harbor in 2008. This innovative hybrid tug will reduce emissions of hazardous and toxic air pollutants and will provide an innovative model for others to follow.
The hybrid tug will combine the technology of modern batteries and an active power management system to minimize engine use. When the engines are used, they will run at power levels which maximize efficiency, which contradicts the current trend of harbor tugs that spend approximately 60 percent of their time at lower power levels with less efficiency. Through the utilization of a hybrid model, main engine emissions will be reduced by about 44 percent for PM and NOx. As a result, fuel consumption is expected to decrease by 20 to 30 percent, which will also reduce levels of SOx and CO2. The primary financial benefits of the design will be accrued through fuel and lube savings and lowered maintenance costs for major equipment components.
Additionally, the tug’s modular design can be applied as a retrofit technology for existing tugboats. The hybrid tug will also be able to incorporate future energy storage improvements in battery technology and hydrogen fuel cells, which leaves ample room for further emissions reductions.
Use of Catalytic Materials for Improved Operation in Abatement of VOC’s in the Semiconductor Industry — Texas Instruments Inc. and Matros Technologies Inc.
Texas Instruments (TI) and Matros Technology (MT) partnered together to reduce emissions at three of TI’s semiconductor manufacturing facilities. Through their collaboration, TI and MT installed the MT copper-chromium catalyst, which reduced NOx emissions and improved VOC performance.
Installation of MT’s catalyst made it possible to combine the low temperature of catalytic oxidation with the high thermal efficiency of regenerative heat exchange, providing three primary environmental benefits. First, due to the much lower oxidation temperature, the regenerative catalytic oxidizer operates using 50 to 60 percent less fuel and generates approximately 40 percent less NOx. Second, due to the nature of the catalyst, greater than 99 percent destruction efficiency can be maintained longer, improving energy recuperation and reducing maintenance activities. Finally, using MT’s catalyst reduces the volume of packing material disposed annually.
Additionally, this technology reduces the use of natural gas as well as materials and labor and disposal costs.
The collaboration of Texas Instruments and Matros Technologies has successfully reduced air emissions and material disposal at Texas Instruments and can be applied globally to similar facilities in the industry.
Development of the XactT Multi-Metals CEMS — Eli Lilly Company, Lafeyette, IN
Eli Lilly and Company (Lilly) and Cooper Environmental Services, LLC, in cooperation with EPA’s Office of Air Quality Planning and Standards, developed, installed, and certified a multi-metals continuous emission monitoring system for use at a rotary-kiln hazardous waste incinerator. Xact™ uses a continuous representative sample of stack gas and X-ray fluorescent technology to quantify a variety of metal emissions. This is the first time that a viable multi-metal continuous monitoring system has been approved by EPA as an alternative compliance indicator for multi-metals emission standards. The Xact™ is not only an excellent tool for hazardous waste incinerators, but the technology and associated certification methodology developed through this project will be applicable and valuable when applied to other sources.
Giving Pollution the Boot — Enviroboot, Environmental Safety Solutions, LLC., New York, NY
Two million construction workers per year are repeatedly exposed to respirable airborne silica dust. In January 2006, Environmental Safety Solutions, LLC (ESS) set a goal of providing adequate protection from airborne contaminates in the work place for the construction and demolition trades and developed EnviroBootTM technology. The EnviroBootTM not only protects workers on the jobsite, but also creates a cleaner environment in the surrounding area and effectively reduces preparation and clean up costs. The technology allows contractors to meet the standard for permissible exposure to crystalline silica set by the federal Occupational Safety and Health Administration, and can help reduce the risk of silicosis, asthma, tuberculosis, and lung cancer in construction workers.
The "HAWK" Leak Detection System — Leak Surveys, Inc., Early, TX
Leak Surveys Inc. (LSI) has contributed to new procedures of leak detection in the field of petroleum processing and improvements in standard leak detection and repair (LDAR). The Hawk Leak Detection System, through the use of a passive infrared camera, has revolutionized the potential for volatile organic compound emission recognition by broadening the scope of detection through the merging of thermal/infrared imaging. The technician scans for emissions while watching a digital video screen to verify a leaking component with their own eyes. From emission compliance to safety concerns to equipment damage, the Hawk has the potential to save companies from lost revenue, damage, and fines while reducing the potential of unacceptable levels of human exposure to toxic substances, fires, explosions, and other serious problems. LSI continues to increase the awareness of the industry, to expand its research and development of optical imaging, and to further refine the technology.
Railpower Switching Locomotives: Ultra Clean Power — Railpower Hybrid Corp., Erie, PA
Railpower Hybrid Technologies Corporation recently released two models of ultra-clean switching locomotives—the Green Goat® hybrid yard switching locomotive and the RP-series branch line or road switcher locomotive. Operating under the slogan “Better Economics, Better Environment,” Railpower has been active in the development, marketing, and production of hybrid technologies applicable in the rail and port sectors. Railpower locomotives have been designated as Ultra Low Emitting Locomotives by the California Air Resources Board and have subsequently been used in government-funded incentive programs, such as the Carl Moyer Program in California and the Texas Emission Reduction Plan. The Green Goat® prototype was developed in 2000, completed in 2001, and tested in 2002. The first hybrid switching locomotive is in service at the Union Pacific Railroad in Roseville, CA; over 100 RailPower Locomotives are currently in service. Railpower produced close to 50 units in 2006 and currently maintains a backlog order of 50 to 100 units.
Alternative Maritime Power — Port of Los Angeles
The Port of Los Angeles Alternative Maritime Power Program is able to reduce the dangerous toxins that surround their port and communities by powering massive container ships with on-shore electricity. By eliminating the use of auxiliary engines during the practice of hotelling container vessels while docked, this technology has shown an average reduction of 95 percent in NOx, SOx, and PM10 per vessel call. Reduction per vessel call in 2004 for NOx, SOx, and PM10 were 0.92, 0.78, and 0.05 tons respectively. Through unique implementation of available technology and providing incentives such as up to $810,000 toward the cost to install the necessary AMP equipment to steamship lines, the Port of Los Angeles’s Alternative Maritime Power program greatly reduces air emissions in the area surrounding the port.
Hybrid Bus Program — King County Metro Transit
King County Metro Transit in Seattle was facing the need to replace an aging bus fleet while ensuring adequate operation of the new vehicles in the transit tunnel under the downtown area. They enlisted a team of manufacturers to develop a prototype clean-air hybrid bus to meet its needs. The new hybrid bus operates on both ultra-low sulfur diesels and electricity generated by batteries stored on the roof. Metro Transit carry passengers on a fleet of 235 hybrid buses, making the environment cleaner and receiving immediate cost savings. Currently, there are over 400 hybrids with the same power package in service at transit agencies throughout the US. The hybrid fleet provides benefits such as savings from the purchase of dual mode buses for the tunnel, a reduction in maintenance staff, a 31 percent increase in fuel economy compared to conventional buses, and more service miles in the first year than the former tunnel fleet at a 37 percent lower cost.
ATmaP™’s Elimination of Solvent-Borne Adhesion Promoting Primers — FTS Technologies and DaimlerChrysler Body-on-Frame Engineering
DaimlerChrysler and FTS Technologies have partnered to eliminate the use of adhesion promoting primers from the manufacturing of automobile exterior parts by implementing Accelerated Thermo Molecular Adhesion Process™. The ATmaP™ process has saved manufacturing costs, improved manufacturing flexibility, and decreased environmental impacts via reduction of emissions and the related contaminated sludge. ATmaP™ does not produce any volatile organic compounds (VOCs) or hazardous air pollutants (HAPs), and the only byproducts are carbon dioxide, nitrogen, heat, and water vapor. The 100 percent elimination of adhesion promoters on the production of motor vehicle chassis components between February and August 2004 resulted in an estimated decrease in VOC and HAP emissions of between 50,000 and 80,000 lbs. DaimlerChrysler continues the conversion towards the use of ATmaP™ to expand VOC and HAP reductions across a greater cross-section of the supply base.
PowerFrame™ Grid Technology — Johnson Controls Battery Group, Inc.
Johnson Controls Battery Group, Inc. replaced an old technology
while keeping environmental impact in mind. The Battery Group
developed PowerFrame™ Grid Technology, a new positive battery
cell grid manufacturing technology, which provides high quality
battery cell grids. The battery cell grids can be produced in
larger quantities while significantly reducing scrap, waste,
and lead emissions. At the heart of this new technology is a
system in which individual grids are “stamped” from
continuous lead sheets in a highly efficient manner. The new
technology does not require the pouring of molten lead into molds
to make the major components of batteries and the inclusion of
air pollution control equipment. Testing indicates that the controlled
lead emissions from the PowerFrame™ process are extremely
low. The net nationwide air quality benefit is a reduction of
550 lbs of lead emissions per year, an average of 79 lbs per
plant. The Johnson Battery Group’s PowerFrame™ technology
provides higher quality products at a lower impact to the environment.
Getting in Gear: Transforming Truck Technology in America — Environmental Defense, FedEx Express, and Eaton Corporation
Environmental Defense, FedEx Express, and Eaton Corporation partnered to bring a cleaner hybrid truck to the market. As of March 2005, 18 low-emission pre-production hybrid electric powered delivery trucks, provided by Eaton Corporation, have been placed into service. Assessed against the standard delivery vehicle in the FedEx fleet, the hybrid truck will reduce smog-causing nitrogen oxide (NOx) emissions by 65%, decrease particulate emissions with the aid of a diesel particulate trap by 96%, reduce emissions of greenhouse gases by 37%, and achieve a fuel economy gain of 57%. FedEx hopes to introduce more of these vehicles into its fleet over time and make this a standard replacement vehicle in its weight class of 30,000 medium-duty trucks. By doing this, smog-causing NOx pollution will be reduced by 2,000 tons a year for every 10,000 conventional FedEx trucks that are replaced by new hybrids.
Evinrude® E-TEC™ Clean Air Technology — Bombardier Recreational Products Inc.
In 2003, Bombardier Recreational Products Inc. (BRP) introduced Evinrude E-TEC, an outboard engine for marine recreational products, which is based on a two-stroke engine technology. Compared to a similar 2004 four-stroke engine, carbon monoxide emissions with Evinrude E-TEC are typically 30 to 50 percent lower; and at idle are lower by a factor of 50 to 100 times. In addition, Evinrude E-TEC emits 30 to 40 percent less total particulate matter on a weight basis than a similar “ultra-low emissions” four-stroke outboard. Furthermore, oxides of nitrogen and hydrocarbon emissions for Evinrude E-TEC are similar, if not lower, than a four-stroke outboard. There are no oil changes with this engine, as well as no belts, and no valve or throttle linkage adjustments. This makes Evinrude E-TEC engines easier to own than comparable four-stroke engines. In addition, numerous advancements combine to create the Evinrude E-TEC quiet signature sound including an exclusive idle air bypass circuit.
Purifil OnGuard Monitors and Enersave — Purifil, Inc.
Purafil, Inc. has been working for over 30 years to provide superior clean air solutions and has made significant advances in the research and development of gas-phase air filtration technology in order to safeguard people and the environment from airborne pollution hazards. Purafil recently developed Enersave, an energy-savings program that reduces the need for outside air by 75% in commercial buildings offering significant savings on energy and operational costs. The Enersave program offers a direct method of eliminating pollutants while also saving money. Companies worldwide now turn to Purafil to conserve energy and maintain a healthy indoor environment. Purafil has also developed monitoring systems that go above and beyond human health standards to protect museums, libraries, archives, and other sensitive conservation environments from permanent damage. The OnGuard Monitors are the world’s first and only instrument capable of providing continuous, real-time measurements of airborne corrosion levels.
Water Dispersible Chemical Agent Resistant Coating — Pennsylvania Army National Guard
The Combined Support & Maintenance Shop (CSMS) East of the Pennsylvania Army National Guard has become the model for pollution prevention in the Army National Guard by replacing its solvent-borne coating with new water dispersible Chemical Agent Resistant Coatings (CARC) for routine surface coating operations. The water dispersible CARC emits virtually no hazardous air pollutants (HAP) and the VOC content is lower than the standard solvent based CARC used throughout the Army, dramatically reducing emissions of these pollutants. It is estimated that switching to water dispersible CARC will reduce VOC emissions by 2.6 tons in the first year. Using water dispersible CARC reduces overspray during the coating process which decreases the volume of paint used and the particulates emitted. Reduced overspray along with less frequent repainting means a reduction in human exposure to the paint.
Remote Smog Check Technology — Networkcar, a Reynolds and Reynolds Company; California
Networkcars remote smog check technology continuously monitors vehicle emissions to detect problems immediately and minimize air pollution. The technology collects detailed information directly from a vehicles engine computer and transmits it wirelessly to an information center, where it is available to car owners, auto dealerships, and fleets in the form of e-mail alerts, summary e-mail reports, and easy-to-read Web pages. Through remote monitoring, car owners are notified automatically if their vehicles fall out of compliance. If the system detects a problem, the owners are notified and have 45 days to repair the problem. Once the problem is repaired, there is no need for a follow-up inspection, as the system is able to detect whether the vehicle is back in compliance. Widespread use of the system would help control emissions of nitrogen oxides, hydrocarbons, and carbon monoxide from consumer and fleet vehicles.
Advanced Travel Center Electrification — IdleAire Technologies Corporation; Nationwide
IdleAire Technologies Corporations Advanced Travel Center Electrification (ATE) technology reduces emissions from idling trucks by inducing truck drivers to turn off their engines while resting. IdleAires ATE technology provides each driver with air conditioning, heating, shore power, high-speed Internet access, e-mail, satellite television, a telephone connection, and free local calls, all for one low hourly rate. The only truck retrofit required is a $10 window adapter, which drivers carry in the cab. IdleAires ATE technology reduces truck idling and emissions and helps improve air quality wherever it is installed.
Ford Fumes to Fuel Process — Ford Motor Company; Dearborn, Michigan
Ford Motor Company and Detroit Edison have developed a process, known as the Fumes to Fuel process, to treat airborne solvent emissions created during automotive painting operations. The Fumes to Fuel process captures solvent-laden air, strips the solvent from the air, concentrates the solvent up to 2,000 times, and sends it to a fuel reformer. The fuel reformer uses the concentrate to generate hydrogen-rich fuel, which is directed into a fuel cell to generate electricity. The system currently generates about 5,000 watts of electricity per hourenough to power an average-sized homeand Ford soon will install a larger system that will be able to generate more than 20 times that amount per hour.
Using Innovative Technology to Minimize HAP Emissions — Packaging Corporation of America; Tomahawk, Wisconsin
Under a cooperative agreement established by the State of Wisconsin and U.S. EPA Region 5, the Packaging Corporation of Americas Tomahawk Mill Plant implemented a new hazardous air pollutant (HAP) control strategy that involves collecting HAP-laden condensate, piping the condensate to an on-site anaerobic digester, and biodegrading the HAPs. Implementing this strategy has improved HAP control by 500 percent.
Refinery Flare Reduction — Flint Hill Resources; Pine Bend, Minnesota and Corpus Christi, Texas
Flint Hill Resources has decreased refinery flare use by 94 percent at two of its major refineries over the past five years and decreased the emissions released during flaring. To reduce flaringa process that safely disposes of hydrocarbons and prevents equipment over pressuring during refining operationsFlint Hill Resources implemented operational controls and improved existing technology. Steps taken by Flint Hill Resources included increasing operator awareness of how to avoid triggering flaring, upgrading its refinery computer control centers, installing alarms that alert operators when flaring conditions occur and allows them ample time to adjust operations to avoid flaring, and upgrading the refineries flare gas recovery systems.
Reduction of Tailpipe Emissions - Biodiesel and Electric Vehicles — U.S. Postal Service; Various Locations Nationwide
Under its Biodiesel Utilization Program, the U.S. Postal Service (USPS) purchases biodiesel, a renewable fuel made from agricultural products, in bulk to fuel its vehicles. Under its Electric Propulsion Vehicle Program, the USPS purchased 500 new zero-emission, battery-powered vehicles for use in hauling and delivery. Through these two programs, the USPS has achieved significant reductions in carbon dioxide, carbon monoxide, hydrocarbons, and other emissions, and serves as a great model for other fleets and the public.
"Yard Hog" Battery Electric Locomotives — Railway Equipment Corporation; Nationwide
To eliminate diesel emissions from idling locomotives, the Railway Equipment Corporation took the initiative to purchase electricity from local power companies and store it in batteries for later use. The use of these lead-acid batteries in the "Yard Hog" locomotive is a cost-effective alternative to diesel locomotives and reduces idling emissions. Additionally, the "Yard Hog" can be easily modified to incorporate technology advancements, rather than having to be replaced.
Ultra Low Sulfur Gasoline — Irving Oil; Portsmouth, New Hampshire
Recognizing that sulfur in gasoline decreases the efficiency and effectiveness of emission-control systems and low emission vehicles, Irving Oil performed a $1 billion upgrade to the Irving Oil Refinery so that it may increase production of its higher-value transportation fuels such as low-sulfur gasoline. In 2000, the refinery became the first in North America to commission full-scale desulfurization technology. Because of these changes, Irving Oil's low sulfur gasoline met 2004 EPA sulfur standards three years ahead of schedule.
VECTM (Virtual Engineered Composites) Technology for Fiberglass Reinforced Plastic Boat Manufacturing — Genmar Holdings, Inc.; Little Falls, Minnesota
The Virtual Engineered Composites Technology (VECTM) system is an automated, computer-monitored process used in fiberglass molding. The VECTM system, a closed-molding system, emits less styrene into the atmosphere and makes an even stronger fiberglass reinforced plastic (FRP) than the open molding process. This system also can be widely applied to non-marine industries manufacturing FRP, another significant source of the United States' styrene emissions.
Super High Solids Ultra-low Emissions Automotive Coating — DaimlerChrysler and DuPont; Newark, Delaware
DuPont and DaimlerChrysler have created and implemented a new paint technology the "Super High Solids" ultra-low emissions clearcoat technology. By using this DuPont product, the DaimlerChrysler Newark facility has realized a 20 percent reduction in topcoat volatile organic compound emissions and an 84 percent decrease in hazardous air pollutant emissions associated with the automotive coating process.
Clean Fuel Buses Program — Metropolitan Transit Authority, New York City Transit Department of Buses; New York City and metropolitan area.
The three core elements of New York City (NYC) Transit's Clean Fuel Bus Program include the purchase of hybrid-electric buses, the use of ultra-low sulfur diesel (ULSD) fuel, and the retrofitting of diesel engines. Through these three elements, the Clean Fuel Bus Program has reduced particulate and nitrogen oxide emissions. NYC Transit's commitment to use ULSD and to retrofit the diesel fleet with filters has allowed them to meet air quality regulations five years in advance of EPA requirements.
Locomotive Emission Reduction System — CSX Transportation, Inc.; 48 contiguous states and Canada.
For the rail industry, CSX Transportation, Inc. (CSXT) has designed, patented, installed, and made available a new Auxiliary Power Unit (APU) system. APU use has reduced emissions of nitrogen oxides by 91 percent, hydrocarbons by 94 percent, carbon monoxide by 96 percent, and particulate matter by 84 percent.
Orbital Combustion Process — Orbital Engine Corporation, Inc.; Tecumseh, Michigan.
Orbital Engine Company has developed a combustion process that achieves significant improvements in both fuel economy and emissions capabilities of gasoline engines. Marine and motorcycle customers currently using the Orbital Combustion Process in their two-stroke engines have reduced emissions by at least 75 percent, while increasing fuel economy by at least 30 percent.
Instantly Available PC Technology — Intel Corporation; Worldwide.
Intel has developed the Instantly Available Personal Computer (IAPC), a computer that can be placed into a deep sleep state, but can be "woken up" very quickly when required. With IAPC technology, power consumption when in standby/sleep mode is under five watts, far exceeding EPA'S ENERGY STAR requirements of 15 watts, while still retaining full communications capabilities in sleep state.
Converting Pulp Mill Waste Gases to Useful Chemicals — Lehigh University, Georgia-Pacific Corp., and Gibson Technologies; Brunswick, Georgia.
The treatment of waste products from the papermaking industry (methanol and mercaptans) releases carbon dioxide, sulfur dioxide, and nitrogen oxides into the atmosphere. This new process allows the paper industry to virtually eliminate these sources of carbon monoxide and nitrogen oxides while making profitable commodity chemicals, formaldehyde and sulfur dioxide, from these waste gases.
Advanced Catalytic Converter Substrates. For many years, Corning Inc. has been developing catalytic converters that reduce mobile source emissions. The incorporation of Corning's advanced substrates into existing and new vehicles will significantly reduce levels of hydrocarbon and nitrogen oxide emissions.
Columbia Boulevard Wastewater Treatment Plant. Portland, Oregon was the first city on the West Coast to use fuel cell technology to convert anaerobic digester gas into electric power. The City installed the fuel cells at its Columbia Boulevard Wastewater Treatment Plant, preventing the annual release of 621 tons of carbon dioxide and reducing methane emissions.
Compression Wave Injection Technology. Developed by John Deere and Company and Design and Manufacturing Solutions, Inc., the Compression Wave Injection technology reduces hydrocarbon and nitrogen oxide emissions and improves fuel economy for two-stroke engines.
XononTM Cool Combustion System. Catalytica Combustion Systems, Inc. has been developing the XononTM Cool Combustion system to reduce nitrogen oxides by 90 percent. XononTM prevents the formation of nitrogen oxides before they can form and has been applied in Santa Clara, California in an industrial gas turbine.
For more information on the Clean Air Excellence Awards Program, contact Pat Childers of EPA's Office of Air and Radiation at (202) 564-1082 or firstname.lastname@example.org.