PEP Announces 2024 Environmental Stewardship Awards

PEP Announces 24th Annual Environmental Stewardship Awards Recipients

AM/NS Calvert - From Waste to Resource: The Impact of Cooling Tower Water Recycling

The Partners for Environmental Progress (PEP) has announced the recipients for their annual Environmental Stewardship Awards. The partners honored this year exhibited an exemplary commitment to protecting and improving our coastal environment, economy and community.  This year’s recipients were officially recognized at the annual meeting on September 5, 2024.

The awards celebrate the innovative approaches our members take to solve environmental problems and enhance the sustainability and resiliency of our coastlines.

The AM/NS Calvert steel mill is located on about 2,400 acres of land, including 160 acres of protected wetlands and has cultivated a strong commitment to wildlife habitat management and environmental sustainability.

In 2023, AM/NS Calvert embarked on a groundbreaking project to recycle S-3a blow-down water back to cooling tower S-3 in collaboration with the Hot Strip Mill’s cooling water circuit team. This project collaborated with the Hot Strip Mill’s cooling water circuit team, their water and waste engineer, and their third-party process chemicals supplier, ChemTreat. The goal was to recycle the blow-down water from cooling tower S-3a back into cooling tower S-3, reducing water waste and chemical usage.

This innovative project involved the installation of a new six-inch diameter stainless steel pipe, which now allows for the recycling of approximately 43 million gallons of industrial water annually. Not only does this project save approximately $76,000 in chemical usage each year, but it also avoids the release of approximately 125,000 pounds of greenhouse gas emissions—the equivalent of the annual energy use of seven homes.

This cooling water recycling project at AM/NS Calvert is a prime example of how industrial operations can align with environmental stewardship. By rethinking waste and finding innovative ways to recycle resources, we can make significant strides toward sustainability.

PEP extends special recognition to ChemTreat for their assistance with this project.

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BASF - Commitment to Sustainability: Reducing Hydrochloric Acid Disposal

BASF has been operational for over 70 years and has two primary production units—the Antioxidants Unit, which produces additives for plastics and lubricants, and the Light Stabilizer Unit, providing materials for paints and coatings.

Historically, the disposal of hydrochloric acid has posed significant environmental and economic challenges. HCl is a byproduct of several industrial processes, and its disposal typically involves neutralization and subsequent discharge, which can lead to CO2 emissions and increased operational costs. Recognizing these challenges, BASF sought a more sustainable solution.

Through a collaborative effort involving the Antioxidant operation and Environmental Health and Safety (EHS) teams, BASF explored alternative outlets for HCl. A critical aspect of BASF’s strategy was enhancing the quality of HCl and finding consistent downstream users.

The successful implementation of these initiatives has led to a significant reduction in HCl disposal, thereby lowering CO2 emissions and operational costs. By finding external outlets for HCl, BASF has turned a potential waste product into a valuable resource, showcasing their commitment to sustainable practices.

BASF’s efforts at the McIntosh site are a prime example of how innovation and collaboration can lead to significant environmental benefits. By reducing the disposal of hydrochloric acid, BASF not only minimizes its environmental footprint and sets a standard for the industry. The dedication and teamwork displayed by the BASF team underscore the importance of sustainable practices and the positive impact they can have on both the environment and business operations.

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FMC - Diamides Process Water Reclamation: Advancing Environmental Stewardship

FMC is a leading agricultural sciences company in Mobile, Alabama. FMC identified a major contributor to waste—over 15 million pounds per year of process waste, predominantly water, which was being incinerated. Utilizing on-site environmental health & safety resources and 3rd party legal experts, the project team completed a successful EPA application to allow onsite treatment to divert 2/3 of the waste from this process to their on-site wastewater treatment plant. 

Thanks to these efforts, 12.3 million pounds of waste and 307 trailer loads of waste per year are now diverted from incineration, leading to a cost savings of $4.5 million annually, projected to rise to $10 million by 2030.

The project has had a profound impact on reducing FMC’s environmental footprint:

  • Greenhouse Gas Reduction:
    • By diverting 12.3 million pounds of waste from incineration, FMC has cut down 575 metric tons of CO2 equivalents annually.
  • Future Improvements:
    • FMC is already exploring additional waste volume reclamation, aiming for a total waste reduction of 80%.

FMC’s diamides process water reclamation project is a testament to the power of innovation and commitment to environmental stewardship. By diverting waste from incineration to on-site treatment, FMC has achieved significant cost savings and reduced its environmental impact. This initiative not only benefits the company but also sets a precedent for sustainable practices in the agricultural sciences industry.

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Moffatt & Nichol - Rising Above the Tides: The Graveline Bay Marsh Restoration Project

Moffatt & Nichol is a global infrastructure advisory firm that provides engineering and consulting services to clients in the marine terminal, transportation, energy, environmental, federal, and urban development markets worldwide. For this project, Moffatt & Nichol acted as the engineering and design team and the construction observation and administration team to restore 60 acres of marsh habitat in Dauphin Island’s Graveline Bay. 

In recent years, the northern Gulf of Mexico’s barrier islands, particularly Dauphin Island, have faced severe environmental challenges. Hurricanes have left their mark, causing island lowering, breaches, and a significant loss of landforms that play crucial roles in the region’s ecological balance. Graveline Bay is a back-barrier island bay that has experienced 75 acres of marsh loss over the last 100 years. The Graveline Bay Marsh Restoration Project was designed to enhance the remaining 37 acres of the marsh by constructing marsh mounds to create intertidal and high marsh habitats while increasing the island’s resilience to storm events.

Based on the funding source, the National Fish and Wildlife Foundation Gulf Environmental Benefit Fund (NFWF GEBF), the overall goal was to restore the ecological functions and services of Graveline Bay marshes to remedy ecological harm from the Deepwater Horizon oil spill. The specific project objectives were to maximize the linear feet of heterogeneous marsh and fringe (edge) habitat and the area of subaerial marsh habitat that could be constructed within the project construction funding amount. These goals and objectives were accomplished by constructing 55 intertidal marsh mounds to attenuate wave activity and create critical marsh edge habitat over the 20-year project lifespan.

The innovative design of the marsh mounds played a crucial role in the project’s success. By focusing on constructing larger, higher mounds to protect smaller, lower-elevation mounds, the project created a robust system that minimized the need for rock breakwaters. This “soft” ecosystem restoration approach led to significant cost savings, costing around $7 per cubic yard compared to a similar project in Florida, costing $25 per cubic yard. This saved the funders approximately $2 million.

The project involved agencies, municipalities, the public, regulatory bodies, and marine contractors. The NFWF GEBF provided funding, with the Alabama Department of Conservation and Natural Resources overseeing the project. The Town of Dauphin Island acted as the project owner, and the Dauphin Island Sea Lab is conducting three years of monitoring.

The Graveline Bay Marsh Restoration Project is a pilot project offering valuable insights for future restoration efforts. Its contractual approach to environmental construction can benefit engineers and contractors, minimizing risks and maximizing ecological benefits. The project’s success in achieving cost savings while enhancing environmental outcomes demonstrates the potential of “soft” ecosystem restoration measures.

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Outokumpu Stainless USA, LLC - Annealing Furnace Energy Efficiency and Natural Gas Reduction and NOx Reduction Project

Outokumpu is a recognized leader in the stainless steel industry. Outokumpu integrates sustainability through their operations, activities and decision-making at the Calvert, Alabama mill. PEP is spotlighting two groundbreaking projects that exemplify Outokumpu’s commitment to a greener future.

Annealing furnaces are essential in processing stainless steel, but they are also significant consumers of natural gas. Outokumpu saw an opportunity to improve the operating efficiency of these furnaces and reduce natural gas consumption—vital for both cost savings and environmental impact. They discovered that applying a high emissivity coating to the inner walls and roof of the furnace could significantly reduce heat loss. This innovative technology, certified by the Space Foundation, enhances radiant heat transfer, thereby lowering the required furnace temperature and reducing natural gas usage.

The results were nothing short of impressive:

  • CO2 Reduction: More than 1,100 tons in 2023
  • Energy Savings: Over 6,100 megawatt-hours (MWh) of energy saved in 2023 alone

Nitrogen oxides (NOx) are harmful pollutants that contribute to air quality issues. At their Calvert mill, Outokumpu set out to reduce NOx emissions in their Hot Annealing and Pickling Line, which utilizes nitric and hydrofluoric acid in its processes.

Outokumpu collaborated with suppliers to trial a process involving the injection of hydrogen peroxide into the acid baths. This innovation allows nitric acid to stay in solution longer, reducing the need for fresh nitric acid and minimizing NOx generation. This also leads to reduced ammonia usage for NOx reduction.

The environmental benefits were substantial:

  • Raw Nitric Acid Reduction: Over 3,000 gallons per month
  • CO2 Reduction: More than 1,400 tons
  • Ammonia Consumption Reduction: 25%

These projects are just two examples of Outokumpu’s unwavering dedication to sustainability and innovation. Their efforts not only enhance operational efficiency but also set a powerful example for the industry.

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Thompson Engineering - Transforming Education and Environment at the Fairhope NEST Learning Campus

Thompson Engineering is a proven leader in the planning, designing, and construction of major transportation, economic development, and waterfront projects across the Southeast. Thompson Engineering worked closely with the project architect, Watershed, and the client, Fairhope Educational Enrichment Foundation. The project utilized the abandoned grounds of a historic school in Fairhope, AL, to provide an outdoor learning laboratory featuring native materials and sustainable living practices.

The Pavilion at the Nest is Phase 1 of a three-phase improvement project. Designed by a talented team of landscape architects, architects, planners, and engineers, this outdoor classroom aims to provide a hands-on educational experience while promoting sustainable living practices. The project’s crowning achievements include receiving Alabama Outdoor Classroom and LEED Gold certifications, emphasizing its commitment to environmental stewardship and education.

The project prominently features a native plant palette that supports local wildlife and provides stormwater treatment. This thoughtful approach not only enhances the learning opportunities for site users but also serves as a natural habitat for various species.

The Fairhope NEST Learning Campus is a shining example of how sustainability and education can go hand in hand. It includes rain gardens, a bluebird box trail, plant identification signage, and a greywater garden that filters and treats grey water biologically. The project even incorporates passive strategies to reduce energy use, such as a double roof system and natural ventilation.

The Fairhope NEST Learning Campus project expands STEAM education opportunities, provides research opportunities, and fosters a deeper understanding of the local ecology. It’s a testament to the community’s dedication to preserving the past while preparing for the future.

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Community Partner Award - Dr. P. J. Waters

Each year, the PEP Board of Directors honors a Community Partner, an entity or an individual that has truly impacted Coastal Alabama’s sustainability and resiliency. PEP’s 2024 Community Partner Award has been presented to Dr. PJ Waters, an Associate Extension Professor at Auburn University.

Dr. Waters has been the catalyst, innovator and “professor of oysters” along the Gulf Coast. He founded the Mobile Bay Oyster Gardening Program, a hands-on oyster restoration and education project that depends on individuals cultivating oysters on their private docs in the coastal waters of Mobile and Baldwin Counties. The volunteer gardeners tend their oysters from May to November when the program then collects, measures, and relocates the grown oysters to an oyster reef in Mobile Bay. Since the program’s inception 23 years ago, more than one million oysters have been grown and relocated. 

Dr. Waters also started The Oyster Trail, an interactive scavenger hunt through Mobile and Baldwin counties. You can’t miss the colorful and educational art of the 26 GIANT statues of painted oysters honoring local scenes along the sidewalks, in parks and at local restaurants and hotels. Each oyster statue is sponsored by a local business or group and is painted by a local artist.

Environmental Impact

PEP is calculating the total greenhouse gas reductions due to the projects selected for the 2024 Environmental Stewardship Awards. These award-winning projects combined resulted in a decrease of 6,732 metric tons of carbon dioxide equivalent emissions last year. According to EPA calculations, this is equivalent to the electricity use of 1,329 homes for one year.

Read more about PEP’s Environmental Stewardship Awards. You can also learn more about the award criteria and application process for 2025.

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