ENVIRONMENTAL PRODUCT DECLARATION for ECONYL BCF REPROCESSED YARNS

Transcription

1 ENVIRONMENTAL PRODUCT DECLARATION for ECONYL BCF REPROCESSED YARNS PCR 212:1 CONSTRUCTION PRODUCTS AND CONSTRUCTION SERVICES, VERSION 2.1, APPENDIX B TO PCR 212:1 CONSTRUCTION PRODUCTS AND CONSTRUCTION SERVICES, VERSION 2.1 CPC: 355 & 264 Revision 1, 1. April 217 Certification No.: Valid until: 5. August 22

2 Rev. 1. April 217 COMPANY Related information 1

3 Rev. 1. April 217 COMPANY RELATED INFORMATION Company related information THE COMPANY Aquafil Group history began in 1969, when the Bonazzi family built the first manufacturing plant in Arco (Trentino Alto Adige region, Italy). In 197, the Group began the polymerization and production of polyamide 6 at this facility, which started Aquafil market share acquisition in the BCF yarn sector (polyamide yarn for textile flooring). During the 8s, significant investments allowed a consolidation and diversification of the Group activities. The most significant diversification of the Group s operation occurred in 1995 when the Aquafil Group finalized the first privatization of a public company in the newly born Republic of Slovenia. This acquisition allowed Aquafil to start its Nylon Textile Filament (NTF) business unit. Meanwhile, the Group continued to widen its product offering by opening a number of production plants in Europe and entering (with its Polyamide products priority focus always in mind) the Engineering Plastics business to supply modified polyamide products to the automotive, electronics and construction industries. At the same time, the Group started its internationalization process with the creation of Aquafil USA, based in Cartersville, Georgia. (USA). Between 2 and 21, the Group expanded its presence in all 3 key markets where it was operating (carpet yarn, textile yarn and engineering plastics), gradually becoming a global leader in the manufacturing of Polyamide 6 fibres. In 213, the Group sold the Engineering Plastics division to DOMO and acquired DOMO s BCF business Xentrys. 2

4 Rev. 1. April 217 COMPANY RELATED INFORMATION The internationalization process continued by adding significant investments in the Asian market where in 25 a manufacturing facility was established in Thailand for processing and marketing BCF products for the carpet industry. In 29, a new manufacturing facility was built in China to assist in the ever-growing Asian market. From , Aquafil developed a visionary project aligned with its manufacturing and market growth focus. Driven by a genuine concern for the environment, resources and investments were dedicated to the design and construction of the ECONYL Regeneration System (the recycling of pre- and post-consumer Polyamide 6 waste material), which launched in 211. As of 214, the Group operates 15 manufacturing plants worldwide with more than 2,7 employees in 8 countries (Italy, Slovenia, Croatia, Germany, United Kingdom, USA, Thailand and China) on 3 continents (Europe, North America and Asia). IT OPERATES 2 DIFFERENT BUSINESS UNITS: BCF Carpet yarn for the flooring market NTF Special yarns for sportswear and fashion applications In 28, during the engineering and design phase of Aquafil s ECONYL Regeneration System, a third business unit was created - Energy & Recycling. TThis Energy & Recycling business unit is dedicated to the promotion of sustainability and environmental issues. It has a transverse nature in respect to the other business units, providing solutions and innovative technologies in the area of energy, recycling and the promotion of the culture of sustainability. 3

5 EPD for Aquafil Econyl Rev. 1. April 217 PRODUCT Related information 4

6 Rev. 1. April 217 Product related information DECLARATION OF GENERAL INFORMATION This environmental product declaration is compliant with ISO 1425 and EN PUBLISHER EPD international AB; Valhallavägen 81, SE Stockholm Sweden; and Institute Bauen und Umwelt e.v. (IBU); Panoramstr.1, 1178 Berlin; OWNER OF THE DECLARATION Aquafil S.p.A., Via Linfano 9, 3862 Arco Italy 2.3 GEOGRAPHICAL SCOPE OF THE EPD Europe 2.4 PRODUCTION SITES INCLUDED IN EPD AquafilSLO - Ljubljana (Letališka cesta 15, 1 Ljubljana, Slovenia) > process B AquafilSLO - Ajdovščina (Tovarniška cesta 15, 527 Ajdovščina, Slovenia) > process A AquafilSLO - Celje (Teharje 15, 3221 Teharje, Slovenia) > process F Aquafil S.p.A. (Via Linfano 9, 3862 Arco, Italy) > process C, D Tessilquattro S.p.A. (Frazione Cares, 3871 Bleggio Inferiore, Italy) > process G AquaSpace S.p.A. (Via del Garda 4, 3868 Rovereto, Italy) > process E AquafilUSA INC. (1 Aquafil Drive & 11 Fiber drive, GA 312, Cartersville, USA) > process Production sites AquafilSLO - Ljubljana, Ajdovščina, Celje and Aquafil S.p.A are ISO 141 certified. 5

7 Rev. 1. April SPECIFICATION OF THE PRODUCT ECONYL BCF yarns are bulk continuous filament yarns, made out of 1 % recycled PA6 polymer. BCF yarns are usually reprocessed by twisting, air entangling and heat setting processes. In some cases they may contain antistatic yarns. As such are delivered to customers for manufacturing carpet tiles and tufted or wowen carpets, within the scope of construction product. > This EPD refers to three groups of Bulk Continuous Filament yarns ECONYL Twisted & Heat-set yarns (dope dyed) ECONYL Air entangled & Twisted yarns (dope dyed) ECONYL Space dyed yarns Environmental performances for each group of yarn is reported separately. Each group of yarn is consisting of several similar products, but differences in terms of parameters are not significant for the first two groups of products (Twisted & Heat-set yarns and Air entangled & Twisted yarns). Meanwhile for the third group of products, the parameters are reported as a range of values, due to higher variation in energy consumption between one product to another in the reprocessing step. 2.6 CONTENT DECLARATION MATERIAL SUBSTANCE WEIGHT (%) CAS NUMBER Polymer Pigments Spin finish Water Polyamide 6 Several Several max Several Several TOTAL 1 - ECONYL BCF yarns do not contain any materials / substances hazardous to health and the environment (carcinogenic, mutagenic or toxic to reproduction, allergic, PBT, vpvb). All ECONYL BCF yarns are OEKOTEX 1 class II certified. 6

8 Rev. 1. April PRODUCT SPECIFICATION >TABLE 2.7.A. ECONYL TWISTED & HEAT-SET YARNS (DOPE DYED) UM VALUE TESTING METHOD Linear density Tenacity at break Elongation at break dtex cn/dtex % ,1-3, DIN 5383 ISO 262 ISO 262 >TABLE 2.7.B. ECONYL AIR ENTANGLED & TWISTED YARNS (DOPE DYED) UM VALUE TESTING METHOD Linear density Tenacity at break Elongation at break dtex cn/dtex % ,1-3, DIN 5383 ISO 262 ISO 262 >TABLE 2.7.C. ECONYL SPACE DYED YARN UM VALUE TESTING METHOD Linear density Tenacity at break Elongation at break dtex cn/dtex % ,1-3, DIN 5383 ISO 262 ISO LCA: CALCULATION RULES 3.1 DECLARED UNIT Declared unit is 1 of ECONYL BCF reprocessed yarn delivered and including primary packaging. 7

9 Rev. 1. April SYSTEM BOUNDARIES This is a»cradle-to-gate«with options EPD, including modules A1-A4 and D module. Modules A1-A3 are reported as one number. Modules A1-A3 include processes, that provide materials and energy input for the system, manufacturing and transport processes up to the factory gate, as well as the waste processing. Module A4 includes transport to the customers. Module D indicates credits resulting from energy recovery of output waste from depolymerisation process. A1-A3 Extraction of resources Waste collected Inorganic synthesis production Crude oil refinery processes USA Fluff/Granulate production Fishnets pretreatment Material storage and handling Waste pretreatment - Ajdovščina (A) Depolymerisation (B) Polymerisation (C) BCF spinning (D) Space dyeing (E) Twisting & heat setting (F) Air entangling & twisting (G) A4 Transportation PROCESSES INCLUDED IN EPD PROCESSES NOT INCLUDED IN EPD 8

10 Rev. 1. April CUT OFF CRITERIA Life Cycle Inventory data for a minimum of 95% of total inflows (mass and energy) module A are included. Auxiliary materials (such lubricating oil, detergents, antifoaming agents..) for which good quality databases were not available, are not included in the study, however are not exceeding the threshold defined above. All the energy inflows were considered in the study 3.4 BACKGROUND DATA All the bacround data relevant for modelling were taken from Gabi database - service pack 3, (update 216). CML 21, January 216 assessment method is used for calculating impacts. 3.5 DATA COLLECTION Life cycle assessment primary data of processes owned by Aquafil group were collected from period of January 216 to December 216, with exception ECONYL plant energy consumption. Primary data for this process is considered from January 217- February 217, to catch the latest improvements of recently implemented projects. 3.6 COMPARABILITY EPDs of construction products may not be comparable if they do not comply with EN

11 Rev. 1. April LCA: SCENARIOS AND OTHER TECHNICAL INFORMATION 4.1 TRANSPORT TO SITE (A4) Means of transport: truck Transport distance: average distance to customers Capacity utilisation: 85% Fuel type: diesel 4.2 REFERENCE SERVICE LIFE This EPD does not indicate RSL. 4.3 MODULE D Waste sludge generated in module A3 is an input to incineration plant located outside Aquafil group. Burdens of incineration are considered in module A, while credits for avoiding production of electrical and thermal energy, in module D. 1

12 Rev. 1. April LCA: RESULTS Product stage Construction process stage Use stage End of life stage Resource recovery stage Raw materials Transport Manufacturing Transport Construction installation Use Maintenance Repair Replacement Refurbishment Operational energy use Operational water use De-construction demolition Transport Waste processing Disposal Reuse-Recovery- Recycling potential A1 A2 A3 A4 A5 B1 B2 B3 B4 B5 B6 B7 C1 C2 C3 C4 X X X X MND MND MND MND MND MND MND MND MND MND MND MND D X (X = included in the LCA; MND = module not declared) 5.1 USE OF RESOURCES >TABLE 5.1.A. ECONYL TWISTED & HEAT-SET YARNS Unit A1-A3 A4 TOTAL D Use of renewable primary energy excluding renewable primary energy resources used as raw materials Use of renewable primary energy resources used as raw materials Total use of renewable primary energy resources; primary energy and primary energy resources used as raw materials Use of non-renewable primary energy excluding non-renewable primary energy resources used as raw materials Use of non-renewable primary energy resources used as raw materials Total use of non-renewable primary energy resources; primary energy and primary energy resources used as raw materials MJ 23,37,2 23,39-1,2 MJ MJ 23,37,2 23,39-1,2 MJ 37,76,44 38,2-4,96 MJ 33,91 33,91 MJ 71,67,44 72,11-4,96 Use of secondary material 1,93 1,93 Use of renewable secondary fuels MJ Use of non-renewable secondary fuels MJ Use of net fresh water m3,11 7,7E-6,11-1,46E-3 11

13 Rev. 1. April 217 >TABLE 5.1.B. ECONYL AIR ENTANGLED & TWISTED YARNS Unit A1-A3 A4 TOTAL D Use of renewable primary energy excluding renewable primary energy resources used as raw materials Use of renewable primary energy resources used as raw materials Total use of renewable primary energy resources; primary energy and primary energy resources used as raw materials Use of non-renewable primary energy excluding non-renewable primary energy resources used as raw materials Use of non-renewable primary energy resources used as raw materials Total use of non-renewable primary energy resources; primary energy and primary energy resources used as raw materials MJ 23,55,2 23,57-1,1 MJ MJ 23,55,2 23,57-1,1 MJ 34,56,44 35, -4,91 MJ 33,59 33,59 MJ 68,15,44 68,59-4,91 Use of secondary material 1,91 1,91 Use of renewable secondary fuels MJ Use of non-renewable secondary fuels MJ Use of net fresh water m3,14 7,7E-6,14-1,45E-3 >TABLE 5.1.C. ECONYL SPACE DYED YARNS Unit A1-A3 A4 TOTAL D Use of renewable primary energy excluding renewable primary energy resources used as raw materials Use of renewable primary energy resources used as raw materials Total use of renewable primary energy resources; primary energy and primary energy resources used as raw materials Use of non-renewable primary energy excluding non-renewable primary energy resources used as raw materials Use of non-renewable primary energy resources used as raw materials Total use of non-renewable primary energy resources; primary energy and primary energy resources used as raw materials MJ 22,74-22,86,2 22,76-22,88 -,99 MJ MJ 22,74-22,86,2 22,74-22,88 -,99 MJ 61,13-78,96,44 61,57-79,13-4,81 MJ 32,93 32,93 MJ 94,6-111,61,44 94,5-112,5-4,81 Use of secondary material 1,82 1,82 Use of renewable secondary fuels MJ Use of non-renewable secondary fuels MJ Use of net fresh water m3,17 7,7E-6,17-1,42E-3 12

14 Rev. 1. April POTENTIAL ENVIRONMENTAL IMPACTS >TABLE 5.2.A. ECONYL TWISTED & HEAT-SET YARNS GWP1* Ozone depletion potential CO 2 CFC-11 3,28 3,1E-8,3 1,47E-13 3,31 3,1E-8 -,87-4,34E-11 Acidification potential SO 2 8,79E-2 1,55E-4 8,94E-2-1,14E-3 Photochemical ozone creation potential Eutrophication potential Abiotic depletion potential (elements) Abiotic depletion potential (fossil) Unit A1-A3 A4 TOTAL D C 2 H 4 PO 4- Sb MJ 8,3E-4 3,1E-3 9,76 36,76 1,73E-5 3,76E-5 2,13E-9,44 8,2E-4 3,5E-3 9,76 37,2-6,57E-5-1,79E-4-3,29E-7-9,49 *emissions and removal of fossil and biogenic carbon are considered >TABLE 5.2.B. ECONYL AIR ENTANGLED & TWISTED YARNS GWP1* Ozone depletion potential CO 2 CFC-11 3,6 3,2E-8,3 1,8E-13 3,9 3,2E-8 -,86-4,3E-11 Acidification potential SO 2 8,48E-3 1,14E-4 8,63E-2-1,13E-3 Photochemical ozone creation potential Eutrophication potential Abiotic depletion potential (elements) Abiotic depletion potential (fossil) Unit A1-A3 A4 TOTAL D C 2 H 4 PO 4- Sb MJ 7,53E-4 2,92E-3 1,1 33,68 1,73E-5 2,77E-5 2,13E-9,44 7,7E-4 2,96E-3 1,1 34,12-9,48E-5-1,78E-4-3,26E-7-9,36 *emissions and removal of fossil and biogenic carbon are considered >TABLE 5.2.C. ECONYL SPACE DYED YARNS GWP1* Ozone depletion potential CO 2 CFC-11 4,96-6,1 3,86E-8,3 1,47E-13 4,99-6,13 3,86E-8 -,84-4,21E-11 Acidification potential SO 2 9,76E-3-1,4E-2 1,55E-4 9,91E-3-1,6E-2-1,1E-3 Photochemical ozone creation potential Eutrophication potential Abiotic depletion potential (elements) Abiotic depletion potential (fossil) Unit A1-A3 A4 TOTAL D C 2 H 4 PO 4- Sb MJ 1,7E-3-1,27E-3 3,42E-3-3,5E-3 7,56 59,86-77,36 1,73E-5 3,76E-5 2,13E-9,44 1,9E-3-1,29E-2 3,46E-3-3,54E-2 7,56 6, - 77,8-9,29E-5-1,74E-4-3,19E-9-9,21 *emissions and removal of fossil and biogenic carbon are considered 13

15 Rev. 1. April OTHER INDICATORS >TABLE 5.3.A. ECONYL TWISTED & HEAT-SET YARNS Unit A1-A3 A4 TOTAL D Hazardous waste disposed 4,8E-2 3,34E-8 4,8E-2-3,49E-9 Non-Hazardous waste disposed 3,82 1,72E-3 3,82-1,2 Radioactive waste disposed 2,7E-4 6,31E-7 2,8E-4-2,45E-4 Components for re-use Materials for recycling Materials for energy recovery Exported energy MJ 4,4 4,4 >TABLE 5.3.B. ECONYL AIR ENTANGLED & TWISTED YARNS Unit A1-A3 A4 TOTAL D Hazardous waste disposed 4,4E-2 3,34E-8 4,4E-2-3,49E-9 Non-Hazardous waste disposed 3,75 1,72E-3 3,75-1,19 Radioactive waste disposed 2,7E-4 6,31E-7 2,8E-4-2,42E-4 Components for re-use Materials for recycling Materials for energy recovery Exported energy MJ 3,99 3,99 >TABLE 5.3.C. ECONYL SPACE DYED YARNS Unit A1-A3 A4 TOTAL D Hazardous waste disposed 5,48E-2 3,34E-8 5,48E-2-3,38E-9 Non-Hazardous waste disposed 3,74-3,77 1,72E-3 3,74 3,77-1,16 Radioactive waste disposed 2,39E-4-2,48E-4 6,31E-7 2,4E-4-2,49E-4-2,38E-4 Components for re-use Materials for recycling Materials for energy recovery Exported energy MJ 3,82 3,82 14

16 Rev. 1. April DIFFERENCES VERSUS PREVIOUS VERSION OF EPD Main reduction of impact GWP compared to previous version of EPD is due to energy efficiency projects implemented in AquafilSLO and better separation of input waste components, before being depolymerised in ECONYL plant. This consuently decreased impacts of sludge waste management generated by depolymerisation stage; thus energy and material efficiency is increased in depolymerisation stage. As indicated in system boundaries, study is newly including: pretreatment process of carpets placed in AquafilUSA fishnets pretreatment carried out by one of the waste suppliers newly implemented pretreatment step in AquafilSLO, which enables better separation of input waste components Hazardous waste quantity is increased due to new waste flow in pretreatment process, which is directed to recycling. 15

17 Rev. 1. April 217 REFERENCES References > Bibliography LCA report, REV.2, 1 April 217 ISO 1425:26 EN 1584:212 General Programme instructions 2.5 PCR 212:1 Construction products and Construction services, Version 2.1, Appendix B to PCR 212:1 Construction products and construction services, Version 2.1 For data elaboration the following tools are used: Software: Gabi 6 Main database: Gabi professional database pack 3 > Contacts To get more information about this environmental declaration or about Aquafil activities please contact: Lucija Aleksić lucija.aleksic@aquafil.com T () > Independent verification Independent verification of the declaration and data, according to ISO 1425: INTERNAL X EXTERNAL Third party verifier: Bureau Veritas, accredited by SWEDAC 15