Heavy industry requires heavy equipment, but the diesel exhaust from these machines can create an unpleasant, potentially unhealthy, work environment. Reducing diesel exhaust exposure is one of Alcoa's health focuses, and this commitment can be seen at the company's Davenport Works in Iowa.
The almost 100 diesel fork-trucks and 40 pieces of heavy equipment that keep this plant running smoothly consume 250,000 gallons of fuel each year. In 2002, the plant switched from diesel fuel to a soy-based biodiesel that greatly reduces exhaust particulate and other emissions from the equipment. Before the switch, employees around the diesel exhaust frequently complained of eye, throat, and respiratory irritation.
"The particular area where I work is well confined with little ventilation," said Ron Pritchard, equipment operator in Davenport's ingot plant. "In the winter when everything was closed up, it became very unpleasant. We had to keep the door open about a foot to keep the fumes moving."
Eliminating diesel equipment wasn't feasible because of the limited capacity of alternative equipment, such as electric-powered vehicles. In 2001, Davenport began evaluating biodiesel, a renewable energy source made from a variety of natural oils. The selected fuel, known as B20, is a 20% blend of soy-based biodiesel and low-sulfur diesel. This blend can be used in new and older diesel engines with no engine modifications and no noticeable impact on the engine's operating performance. The fuel, which is slightly more expensive than diesel, also can prolong engine life.
Results of the evaluation indicated that the ambient concentration of diesel exhaust particulate in high traffic areas decreased 80%. Tailpipe emissions were reduced by 44.2%, and additional benefits included a reduction in hydrocarbon, sulfur dioxide, carbon monoxide, and carbon dioxide emissions. In addition, the objectionable odor of diesel exhaust changed to the odor of French fries.
In 2002, Davenport switched from diesel to biodiesel for all powered equipment. The change, which involved no additional expense, reduced employee health risks, decreased the use of fossil fuels, and reduced emissions into the environment.
"After we switched to the new fuel, the air cleared up quite a bit," said Pritchard. "We don't have the burning eyes and throats like we used to."
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