Sustainable fiber production

Transcription

1 Sustainable fiber production Resource efficiency and reduction of environmental impact at Lenzing AG Andrea Borgards Marion Schiemer May 23, 2011 Vienna 23./24. May 2011, Vienna 1/ 23

2 Contents Global l fiber demand d and Lenzing s role in the fiber business Advances in dissolving pulp production Advances in fiber production Energy Life cycle analysis Sustainability in a broader approach Summary and Outlook 23./24. May 2011, Vienna 2/ 23

3 Global fiber demand 2010 Wool 1.6% Natural Fibers & Natural Polymers Cotton 33.5% 73.8 mill. t Synthetic Fibers 58.4% Man made cellulosic fibers 5.7% Cellulose Gap 0.8% Source: The Cellulose Gap, Gherzi, February 2011 Total fiber demand: approx. 73 Mio t/a. 23./24. May 2011, Vienna 3/ 23

4 The basic concept of manmade cellulosic fibers powered by the sun 23./24. May 2011, Vienna 4/ 23

5 The Lenzing group 2010 Core business: cellulosic l fibers (world market leadership) Majority holder: B & C Holding GmbH, Austria (90,54 %) Total production 2010 ~ t/a Sales: 1.766,3 mio. Export share: 91,3 % Staff: /24. May 2011, Vienna 5/ 23

6 Pulp Production sites Lenzing / Upper Austria Biocel Paskov / Czech Republic Wood source: beech t/a dissolving pulp Acid Mg-Bisulfite pulping TCF bleaching Wood source: spruce t/a paper pulp at the moment switch operation planned Acid Mg-Bisulfite pulping ECF bleaching 23./24. May 2011, Vienna 6/ 23

7 Fiber Production sites Lenzing / A Purwakarta / ID Nanjing / CN VISCOSE capacities: t/a Mobile / USA Grimsby / GB Heiligenkreuz / A TENCEL capacities: t/a 23./24. May 2011, Vienna 7/ 23

8 Wood analysis: Beech 23./24. May 2011, Vienna 8/ 23

9 Pulp production at Lenzing site, A 23./24. May 2011, Vienna 9/ 23

10 Xylose Degradation of Xylan into Xylose during acid bisulfite cooking Reduction to Xylitol after separation (Danisco) Applications: Sweetening agents caries prophylaxis wetting agents (nasal spray) 23./24. May 2011, Vienna 10 / 23

11 Extraction of furfural and acetic acid from waste water furfural 23./24. May 2011, Vienna 11 / 23

12 Furfural Produced d from Xylose during cooking Utilization as: Production of furfurylic alcohol Solvent for lubricant refining Solvent for Anthracene and resins Distillation of Butadiene Marker for fuel oil Production of herbicides 23./24. May 2011, Vienna 12 / 23

13 Over 50% of wood is used for products, residual for process energy 23./24. May 2011, Vienna 13 / 23

14 Viscose fiber production CS 2 and S Recycling 23./24. May 2011, Vienna 14 / 23

15 Tencel fiber production Advantages compared to viscose less complex process high h recovery rate of dissolving i agent NMMO >99% fiber quality like high end combed ELS grade cotton types 23./24. May 2011, Vienna 15 / 23

16 Application fields of Lenzing fibers Textile industry Fashion, home textiles, technical applications Advantages Breathable Biocompatible Dyeing performance Moisture management Ideal polyester blending fiber Nonwovens industry Medical and technical applications, Hygiene, cosmetics Naturally absorbent Fully biodegradable 23./24. May 2011, Vienna 16 / 23

17 Commitment t to the environment Over the same period the production capacity was more than doubled /24. May 2011, Vienna 17 / 23

18 Life cycle analysis Significant lower environmental impact vs. cotton Substitution of Lenzing fiber production with cotton would cause additional emission of 300,000 tons of carbon dioxide, require an additional 340,000 hectares of arable land and consume an additional 2.2bn cubic meters of water Water Consumption Required Acreage for Production of One Metric Ton of Fiber Environmental Impact of Production (1) m 3 per metric ton of fiber Hectares per metric ton and year Relative to cotton ca. 20x 5, % ca. 3x 0.82 ca. 18x % 5.7% TENCEL Cotton TENCEL Austria USA and China Austria Cotton USA and China Lenzing Group Avg. Cotton USA and China Process water Surface water irrigation Cooling water Groundwater irrigation Source: Life Cycle Assessment of Man-made Cellulose fibers ; Li Shen, Martin Patel; 2007 LAG 1. including freshwater ecotoxicity, terrestrial ecotoxicity and others 23./24. May 2011, Vienna 18 / 23

19 Comparison of energy sources 23./24. May 2011, Vienna 19 / 23

20 Sustainability at Lenzing Sustainable economic success Growth, innovation, productivity Technology leadership, quality leadership Responsibility for the environment Lenzing sets environmental standards Closed loops and integration Renewable resource wood Superior recovery of energy and co-products Responsibility for the people Attractive jobs High safety and health standards Regional support of social, sports and cultural activities 23./24. May 2011, Vienna 20 / 23

21 Summary and Outlook Lenzing s most important steps towards sustainable fiber production: Use of renewable, certified wood sources Increased use of non-fossil fuels for energy efficient processes Constant improvements in closing chemical and water cycles Mg/SO 2 recovery for pulping CS 2 recycling for viscose making NaOH reuse from viscose waste in pulp bleaching Zn recycling from waste water for spin bath preparation Starting 2011: Further closure of TCF pulp bleach plant by innovative bleaching sequence Development and investment of Tencel technology for fiber production Production of economically viable co-products from waste streams Xylose, Furfural, Acetic Acid Na 2 SO 4 Starting 2012: heavy soda Investments in air emission and waste water treatment plants, aerobic plus anaerobic 23./24. May 2011, Vienna 21 / 23

22 Certificates, Eco-Labels and Awards VÖNIX (Austrian Sustainability Index) CSR ranking Austria 2008 The European Eco-Label (European Flower) Responsible Care Panda - WWF Austria (2003) Compostable (DIN CERTO) Oeko-Tex Standard 100 European p Award for the environment Nordic Swan ECO Responsibility Award by TENCEL SUN (2011) PEFC (Chain of Custody) FSC (Chain of Custody) 23./24. May 2011, Vienna 22 / 23

23 Thank you for your attention! 23./24. May 2011, Vienna 23 / 23