Rather than take a low-risk, low-effort approach to reduce hazardous air pollutants (HAP), Alcoa’s Warrick Operations in Indiana chose to reformulate the coatings it uses to gain long-term environmental and economic benefits. The project took nine years to complete.
Warrick operates an electro-coat water-based coating line to produce aluminum sheet used for beer can lids. The operation used a number of solvents that were hazardous air pollutants. When new regulations required a reduction in these pollutants, Warrick could have either installed an incinerator to control the emissions or reformulated the coating to include the use of non-HAP solvents.
While the incinerator would have been the fast and easy option, Warrick chose to pursue reformulation. This entailed many steps, including developing the coating, perfecting the electro-coating process using the new solvents, and conducting qualification trials for process capability and product performance. Performance criteria included formability, corrosion resistance, effect on product taste, and appearance.
Warrick worked with the Alcoa Technical Center and PPG Industries develop a new coating called ALC-132. The facility also worked closely with each customer to evaluate and qualify the new coating and to ensure a smooth commercial transition to the new coated product.
The conversion provided the following benefits:
- HAP emissions were reduced by 82%, which translates into approximately 250,000 pounds of HAPs not emitted each year.
- By not using the incinerator option, Warrick saved 80 million cubic feet of natural gas annually and avoided the following additional air pollutants: 12,300 pounds of nitrogen oxides, 3,100 pounds of carbon monoxide, 1,200 of fine particular matter, and 10.5 million pounds of carbon dioxide.
- Warrick avoided a $2 million capital investment in an incinerator and more than $500,000 annually in natural gas costs.
The project received a 2005 Alco EHS Achievement Award.
|
 |
Working to Reduce Greenhouse Gases
By reducing anode effect problems, Alcoa has met established greenhouse gas emission reductions and is making progress toward reaching new reduction goals.
 more
Continuing to Reduce Greenhouse Gas Emissions
Major participants in the aluminum industry and the Quebec government sign an agreement to voluntarily reduce greenhouse gas emissions by nearly 200,000 tons from Quebec-based facilities by 2007.
more
Replacing Equipment, Reducing Emissions
Equipment replacements at Alcoa-Köfém in Hungary and the Ludwigshafen facility in Germany reduced emissions and energy consumption.
more
Soliciting the External Viewpoint
Alcoa's Warrick Operations in Indiana uses an environmental forum and community report to solicit stakeholder views.
more
|
