ENVIRONMENTAL PRODUCT DECLARATION for ECONYL NYLON TEXTILE FILAMENT YARNS

Transcription

1 ENVIRONMENTAL PRODUCT DECLARATION for ECONYL NYLON TEXTILE FILAMENT YARNS CPC263&264TEXTILE YARN AND THREAD OF NATURAL FIBERS, MANMADE FILAMENTS OR STAPLE FIBRES PCR2013:12 VERS Revision 2, 10. April 2017 Certification No.: SP00278 Valid until: 28. Auust 2020

2 EPD for Aquafil ECONYL Rev. 1, 10. April 2017 COMPANY AND PRODUCT Related information 1

3 EPD for Aquafil ECONYL COMPANY AND PRODUCT RELATED INFORMATION Company and product Related information THE COMPANY Aquafil Group history bean in 1969, when the Bonazzi family built the first manufacturin plant in Arco (Trentino Alto Adie reion, Italy). In 1970, the Group bean 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 floorin). Durin the 80s, sinificant investments allowed a consolidation and diversification of the Group activities. The most sinificant 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) product area. Meanwhile, the Group continued to widen its product offerin by openin a number of production plants in Europe and enterin the Enineerin Plastics business to supply modified polyamide products to the automotive, electronics and construction industries with the polyamide products priority focus always in mind. At the same time, the Group started its internationalization process with the creation of Aquafil USA, based in Cartersville, Georia. (USA). Between 2000 and 2010, the Group expanded its presence in all 3 key markets where it was operatin (carpet yarn, textile yarn and enineerin plastics), radually becomin a lobal leader in the manufacturin of Polyamide 6 fibers. In 2013, the Group sold the Enineerin Plastics division to DOMO and acquired DOMO s BCF business Xentrys. 2

4 EPD for Aquafil ECONYL COMPANY AND PRODUCT RELATED INFORMATION The internationalization process continued by addin sinificant investments in the Asian market where in 2005 a manufacturin facility was established in Thailand for processin and marketin BCF products for the carpet industry. In 2009, a new manufacturin facility was built in China to assist in the everrowin Asian market. From , Aquafil developed a visionary project alined with its manufacturin and market rowth focus. Driven by a enuine concern for the environment, resources and investments were dedicated to the desin and construction of the ECONYL Reeneration System (the recyclin of pre and postconsumer Polyamide 6 waste material), which launched in As of 2014, the Group operates 15 manufacturin plants worldwide with more than 2,400 employees, in 8 countries (Italy, Slovenia, Croatia, Germany, United Kindom, USA, Thailand and China) on 3 continents (Europe, North America and Asia). IT OPERATES 2 DIFFERENT PRODUCT AREAS: BCF Carpet yarn for the floorin market NTF Special yarns for sportswear and fashion applications In 2008, durin the enineerin and desin phase of Aquafil s ECONYL Reeneration System, a new department was created Enery & Recyclin. This Enery & Recyclin department is dedicated to the promotion of sustainability and environmental issues. It has a transverse nature in respect to the other product areas, providin solutions and innovative technoloies in the area of enery, recyclin and the promotion of the culture of sustainability. 3

5 EPD for Aquafil ECONYL COMPANY AND PRODUCT RELATED INFORMATION SPECIFICATION OF MANUFACTURING COMPANY AND PRODUCT This environmental product declaration is compliant with ISO and EN SPECIFICATION OF MANUFACTURING COMPANY Manufacturin Company: Aquafil s.p.a. (Italy) Production sites involved in EPD: AquafilSLO d.o.o. Ljubljana (Letališka cesta 15, 1000 Ljubljana, Slovenia) > process B, C, D & E AquafilSLO d.o.o. Ajdovščina (Tovarniška cesta 15, 5270 Ajdovščina, Slovenia) > process A AquafilCRO d.o.o. (Ul. Milana Prpića 114, 49243, Oroslavje, Croatia) > process F AquafilSLO d.o.o. Senožeče (Senožeče 151, 6224 Senožeče, Slovenia) > process G AquafilUSA INC. (1 Aquafil Drive & 101 Fiber drive, GA 30120, Cartersville, USA) > process H Production country: Slovenia, Croatia Reference markets: apparel industry Production sites AquafilSLO Ljubljana, Ajdovščina, Senožeče, AquafilCRO and Aquafil S.p.A are ISO certified. 2.2 SPECIFICATION OF THE PRODUCT > This EPD refers to two types of Nylon Textile Filament yarns: ECONYL FDY yarns on beam ECONYL texturized yarns on cones Both types of yarns are produced out of 100 % recycled PA6 polymer, with postconsumer and postindustrial recycled content certified by independent third party DNV PCITADNV. 4

6 EPD for Aquafi l ECONYL COMPANY AND PRODUCT RELATED INFORMATION TECHNICAL SPECIFICATION NAME TEST METHOD Commercial article description Basic polymer; % of basic polymer / Generic name of synthetic fiber; % of synthetic fiber Type of yarn or fiber Type of processin Intended use Resultin linear density Filament number ECONYL FDY yarn on beams 100% Polyamide 6 Filament yarn Fully Drawn Yarn See section dtex78 dtex various EN ISO 10431:2011 ISO 2076 : 2010 ISO 8159:1987 BISFA ISO TECHNICAL SPECIFICATION NAME TEST METHOD Commercial article description Basic polymer; % of basic polymer / Generic name of synthetic fiber; % of synthetic fiber Type of yarn or fiber Type of processin Intended use Resultin linear density Filament number ECONYL textured yarn on cones 100% Polyamide 6 Textured Filament yarn Partially Oriented Yarn / False Twist Texturizin See section dtex120 dtex various EN ISO 10431:2011 ISO 2076 : 2010 ISO 8159:1987 BISFA ISO ECONYL yarns do not contain any materials / substances hazardous to health and the environment (carcinoenic, mutaenic or toxic to reproduction, alleric, PBT, vpvb). All Nylon Textile Filament ECONYL yarns are OEKOTEX 100 class I certifi ed. 3 DECLARED UNIT Functional unit is 1 k of yarn delivered. 5

7 EPD for Aquafi l ECONYL COMPANY AND PRODUCT RELATED INFORMATION 4 CONTENT DECLARATION All the yarns concerned by this declaration are made by polyamide 6, piment (in most cases titanium) and spin fi nish. For its hydrophilic nature, polyamide yarn has a humidity content of about (34) %, dependin on the environmental relative humidity. Its composition is: A. ECONYL FDY YARNS ON BEAM TYPE OF PRODUCT/SERVICE % OF MATERIAL BY WEIGHT (OF WHICH) % RECYCLED Polyamide 6 Piments Spin Finish Water Percent of which main materials, piments and dye stuff, and other materials is biobased Of which postconsumer waste Of which preconsumer waste ,6 1,01, % 0% 100 % 0% 0% 0% 50% 50% B. ECONYL TEXTURISED YARNS ON CONES TYPE OF PRODUCT/SERVICE % OF MATERIAL BY WEIGHT (OF WHICH) % RECYCLED Polyamide 6 Piments Spin Finish Water Percent of which main materials, piments and dye stuff, and other materials is biobased Of which postconsumer waste Of which preconsumer waste ,4 1,52, % 0% 100 % 0% 0% 0% 50% 50% 5 AND QUANTITIES SI units are used. 6

8 EPD for Aquafil ECONYL COMPANY AND PRODUCT RELATED INFORMATION 6 GENERAL SYSTEM BOUNDARIES UPSTREAM Extraction of non renewable resources USA Fluff/Granulate production (H) PA6 Fishin nets pretreatment Inoranic synthesis production Crude oil refinery processes PA6 Olyomers collection PA6 other waste collection Additives and auxiliary Waste pretreatment Ajdovščina (A) Material storae and handlin Depolymerisation (B) Polymerisation (C) CORE Spinnin POY (D) Spinnin FDY (E) Texturisin (F) Warpin (G) Delivery Use Phase Product packain and end of life PROCESSES INCLUDED IN EPD PROCESSES NOT INCLUDED IN EPD 7

9 EPD for Aquafil ECONYL COMPANY AND PRODUCT RELATED INFORMATION In eneral, Life Cycle Inventory data for a minimum of 95% of total inflows (mass and enery) to the upstream and core module is included. Auxiliary materials (such as lubricatin oil, deterents, antifoamin aent..) for which ood quality databases were not available, are not included in the study, however are not exceedin the threshold defined above. All enery inflows are considered in the study. 6.1 UPSTREAM PROCESSES Upstream processes include: extraction of nonrenewable resources additives and auxiliaries production all relevant transportation secondary raw materials, that are enterin into pretreatment plant and are constituted of three main types of waste: A. PA6 fishin nets collection: they are collected worldwide B. PA6 carpets are collected, and are shaved to obtain PA6 fluff or ranules C. Oliomers and other plastics waste enerated by polymer industries Dependin on the type and shape of waste, it can be cleaned, sorted, rinded, washed, ranulated or pelletized. All waste material is characterized with the specific feedstock enery enterin the system, and the processes are described by means of enery use and emissions. ECONYL plant operation A. washin (if and when necessary) B. depolymerization (where specific mix of waste is transformed back into secondary raw material caprolactam) C. purification of caprolactam polymer production All eneretic input flows (electricity, heatin fuels, steam...) and water consumption to the upstream processes are considered. All emissions to air, water and soil and treatment of waste and wastewater enerated are considered as well. 8

10 EPD for Aquafil ECONYL COMPANY AND PRODUCT RELATED INFORMATION 6.2 CORE PROCESSES Core Process takes into account: spinnin process (POY or FDY) post spinnin processes; texturizin or warpin transportation of materials into the core processes All eneretic input flows (electricity, heatin fuels, steam...) and water consumption to the upstream processes are considered. All emissions to air, water and soil and treatment of waste and wastewater enerated are considered as well. 6.3 PROCESSES Downstream processes include transportation to averae retailer / distribution platform: 300 km by truck Use phase and end of life of product is not included. 7 ENVIRONMENTAL PERFORMANCE RELATED INFORMATION The environmental burden of the product has been calculated accordin to the eneral rules of the EPD (Environmental Product Declaration) international proramme and PCR 263&264 (Textile yarn and thread of natural fibers, manmade filaments or staple fibers). This declaration is based on the application of Life Cycle Assessment (LCA) methodoloy to the Econyl yarns lifecycle system. The LCA report constitutes the most important backround document to support environmental communication about ECONYL and its environmental lifecycle burden. 9

11 EPD for Aquafil ECONYL ENVIRONMENTAL PERFORMANCE RELATED INFORMATION To assess the burden of ECONYL yarn production at the plant level, detailed data and information were collected from several manufacturin facilities: AquafilUSA; USA (for ECONYL carpet waste pretreatment) AquafilSLO Ajdovščina; Slovenia (for ECONYL waste pretreatment) AquafilSLO Ljubljana; Slovenia (for ECONYL depolymerization, polymer manufacturin and spinnin of yarns) AquafilSLO Senožeče; Slovenia (for post spinnin processinwarpin) AquafilCRO; Croatia (for post spinnin processintexturizin) Customized LCA questionnaires were used to ather indepth information about all aspects of the production system (for example, raw materials specifications, pretreatments, process efficiencies, air emissions, waste manaement), ultimately providin a complete picture of the environmental burden of the system. The use phase and end of life are not included in the study, while distribution scenario is set to 300 km via truck to distribution platform. ECONYL production process is continuously improved and this analysis took into consideration the most representative and specific data available. From a eneral point of view, all of the plants are described usin primary data from January 2016December 2016, with exception of ECONYL plant enery consumption. Primary data for this process is considered from January 2017 February 2017, to catch the latest improvements of recently implemented projects. 7.1 RESOURCES RESULTS ABOUT THE USE OF RESOURCES ARE SPLIT INTO FOUR SECTIONS: Renewable resources Table 1 Nonrenewable resources Table 2 Secondary resources Table 3 Direct electricity consumption Table 4 Water use Table 5 10

12 EPD for Aquafi l ECONYL ENVIRONMENTAL PERFORMANCE RELATED INFORMATION >TABLE 1.A. RENEWABLE RESOURCES FOR PRODUCTION OF 1 KG OF ECONYL FDY yarn on beamsrounded values RR MATERIAL RESOURCES () Enery resources for enery conversion purpose [MJ] RR ENERGY RESOURCES (MJ) Solar 2,13 1,46E02 2,15 Hydropower Wind 25,47 2,00 2,53E04 1,78E04 25,47 2,00 Biomass Other 0,22 1,46E03 29,83 0,00 1,06E05 1,50E02 0,22 1,47E03 29,84 Totals may not match, because of rounded data >TABLE 1.B. RENEWABLE RESOURCES FOR PRODUCTION OF 1 KG OF ECONYL texturized yarn on conesrounded values RR MATERIAL RESOURCES () Enery resources for enery conversion purpose [MJ] RR ENERGY RESOURCES (MJ) Solar 2,97 1,46E02 2,99 Hydropower Wind 27,02 1,97 2,53E04 1,78E04 27,02 1,97 Biomass Other 0,51 1,41E03 32,48 0,00 1,06E05 1,50E02 0,51 1,42E03 32,49 Totals may not match, because of rounded data >TABLE 2.A. NONRENEWABLE RESOURCES FOR PRODUCTION OF 1 KG OF ECONYL FDY yarn on beams rounded values NR MATERIAL RESOURCES () Inert rock 4,07E+03 0,78 4,07E+03 Limestone (CaCo 3 ) 120,12 0,06 120,18 Sodium Chloride 10,40 3,22E03 10,44 Soil 353,89 9,40E03 353,90 Natural areate 244,73 2,55E03 244,73 Clay 49,18 1,15E03 49,18 Others 34,06 0,35 34,41 NR MATERIAL RESOURCES () 4,86E+03 1,21 4,86E+03 NR ENERGY RESOURCES FOR ENERGY CONVERSION PURPOSE () Hard coal 514,08 0,03 514,11 Crude oil 146,55 5,70 152,25 Linite 35,71 0,37 36,08 Natural as 88,29 0,49 88,78 Uranium 1,04E03 1,75E06 1,04E03 Other 0,05 5,81E04 0,05 NR ENERGY RESOURCES () 784,68 6,26 790,94 Totals may not match, because of rounded data 11

13 EPD for Aquafi l ECONYL ENVIRONMENTAL PERFORMANCE RELATED INFORMATION >TABLE 2.B. NONRENEWABLE RESOURCES FOR PRODUCTION OF 1 KG OF ECONYL texturized yarn on cones rounded values NR MATERIAL RESOURCES () Inert rock 4,04E+03 0,78 4,04E+03 Limestone (CaCo 3 ) 119,72 0,06 119,79 Sodium Chloride 11,07 3,22E03 11,07 Soil 356,45 9,40E03 356,46 Natural areate 232,34 2,55E03 232,34 Clay 48,78 1,15E03 48,78 Others 35,06 0,35 35,41 NR MATERIAL RESOURCES () 4,84E+03 1,21 4,84E+03 NR ENERGY RESOURCES FOR ENERGY CONVERSION PURPOSE () Hard coal 502,42 2,93E02 502,45 Crude oil 159,76 5,70 165,46 Linite 46,69 3,86E02 46,73 Natural as 110,29 0,49 110,78 Uranium 1,38E03 1,75E06 1,38E03 Other 0,05 5,81E04 0,05 NR ENERGY RESOURCES () 819,22 6,26 825,48 Totals may not match, because of rounded data >TABLE 3. SECONDARY MATERIAL RESOURCES FOR PRODUCTION OF 1 KG OF ECONYL yarn RECYCLED WASTE ECONYL FDY yarn 1,81E ,81E+03 ECONYL texturized yarn 1,78E ,78E+03 >TABLE 4. DIRECT ELECTRICITY USED FOR PRODUCTION OF 1 KG OF ECONYL yarn ECONYL FDY yarn kwh 5,65 0 5,65 ECONYL texturized yarn kwh 6,20 0 6,20 >TABLE 5.A. WATER USED FOR PRODUCTION OF 1 KG OF ECONYL yarn ECONYL FDY yarn liter 23,04 0,43 23,47 ECONYL texturized yarn liter 25,79 0,43 26,22 Totals may not match, because of rounded data >TABLE 5.B. WATER USED IN CORE MODULE FOR PRODUCTION OF 1 KG OF ECONYL yarn ECONYL FDY yarn ECONYL texturized yarn liter liter CORE 3,45 4,68 Totals may not match, because of rounded data 12

14 EPD for Aquafi l ECONYL ENVIRONMENTAL PERFORMANCE RELATED INFORMATION 7.2 POTENTIAL ENVIRONMENTAL IMPACT >TABLE 6.A. ENVIRONMENTAL IMPACT FOR PRODUCTION OF 1 KG OF ECONYL FDY yarn on beams; CML2001, January 2016 Global Warmin Potential (GWP) fossil * CO 2 eq 2,44E+03 19,40 2,46E+03 Global Warmin Potential (GWP) bioenic * CO 2 eq 71,79 0,21 72,00 Acidification Potentials SO 2 eq 7,72 0,09 7,81 Photochemical Ozone Creation P. Eutrophication Potentials C 2 H 4 PO 4 eq 0,63 3,68 0,01 0,02 0,65 3,70 Totals may not match, because of rounded data *emissions and removals are considered >TABLE 6.B. ENVIRONMENTAL IMPACT FOR PRODUCTION OF 1 KG OF ECONYL texturized yarn on cones; CML2001, January 2016 Global Warmin Potential (GWP) fossil * CO 2 eq 2,49E+03 19,40 2,51E+03 Global Warmin Potential (GWP) bioenic * CO 2 eq 253,79 0,21 254,00 Acidification Potentials SO 2 eq 8,06 0,09 8,15 Photochemical Ozone Creation P. Eutrophication Potentials C 2 H 4 PO 4 eq 0,75 3,46 0,01 0,02 0,76 3,48 Totals may not match, because of rounded data *emissions and removals are considered Waste raw materials have very little infl uence on the indicators above. Depolymerization (with specifi c concern to coal based steam production and thermal recovery from depolymerization waste) is the primary contributor to GWP. Polymerization, spinnin, texturizin and warpin are still important, but the contribution is of lower rade, mostly because of the renewable mix for specifi c direct electricity. In addition, use of auxiliary chemical used for depolymerization process is sinifi cantly contributin to Eutrophication Potential. 7.3 OTHER INDICATORS >TABLE 7.A. RECYCLED MATERIAL CONTENT FOR PRODUCTION OF 1 KG OF ECONYL FDY yarn on beams UPSTREAM CORE POST CONSUMER % POST INDUSTRIAL % min. 50 min. 50 max. 50 max

15 EPD for Aquafi l ECONYL ENVIRONMENTAL PERFORMANCE RELATED INFORMATION >TABLE 7.B. RECYCLED MATERIAL CONTENT FOR PRODUCTION OF 1 KG OF ECONYL texturized yarn on cones UPSTREAM CORE POST CONSUMER % POST INDUSTRIAL % min. 50 min. 50 max. 50 max. 50 >TABLE 8.A. WASTE AT PRODUCTION OF 1 KG OF AVERAGE ECONYL FDY yarn on beams Hazardous waste 1,36 3,79E04 1,36 Non hazardous 4,96E+03* 1,03 4,96E+03 Radioactive 0,11 0 0,11 *more than 80% of the waste is enerated by extraction of coal and linitestockpile oods deposited >TABLE 8.B. WASTE AT PRODUCTION OF 1 KG OF AVERAGE ECONYL texturized yarn on cones Hazardous waste 1,40 3,79E04 1,40 Non hazardous 4,94E+03* 1,03 4,94E+03 Radioactive 0,17 0 0,17 *more than 80% of the waste is enerated by extraction of coal and linitestockpile oods deposited >TABLE 9.A. WASTE AT PRODUCTION OF 1 KG OF ECONYL FDY yarn on beams waste subject to recyclin Hazardous waste 33,42 0,00 33,42 Non hazardous 119,48 0,00 119,48 >TABLE 9.B. WASTE AT PRODUCTION OF 1 KG OF ECONYL texturized yarn on cones waste subject to recyclin Hazardous waste 32,92 0,00 32,92 Non hazardous 104,95 0,00 104,95 >TABLE 10. WASTE GENERATED IN THE CORE MODULE FOR PRODUCTION OF 1 KG OF ECONYL yarn HAZARDOUS WASTE WASTE GOING TO RECYCLING ECONYL FDY yarn K 4,62E04 0,11 0,95 ECONYL texturized yarn K 5,49E04 0,10 0,84 The impacts related to the manaement of the waste all alon the life cycle are included in the impact assessment reported in chapter

16 EPD for Aquafi l ECONYL ENVIRONMENTAL PERFORMANCE RELATED INFORMATION >TABLE 11. FRESHWATER ECOTOXICITY FOR PRODUCTION OF 1 KG OF ECONYL yarn ECONYL FDY yarn K DCB e. 0,17 1,13E04 0,17 ECONYL texturized yarn K DCB e. 0,18 1,13E04 0,19 >TABLE 12. BYPRODUCT GENERATED FOR PRODUCTION OF 1 KG OF ECONYL yarn QUANTITY TYPOLOGY ECONYL FDY yarn MJ 2,14 THERMAL ENERGY ECONYL texturized yarn MJ 2,11 THERMAL ENERGY Thermal enery is considered as byproduct and carries 6% of the total environmental burdens in the stae of caprolactam production. 8 DIFFERENCES VERSUS PREVIOUS VERSION OF EPD Main reduction of impact GWP compared to previous version of EPD is due to enery effi ciency projects implemented in Aquafi lslo and better separation of input waste components, before bein depolymerised in ECONYL plant. This consequently decreased the impacts of slude waste manaement enerated by depolymerisation stae; thus, enery and material effi ciency is increased in depolymerisation stae. As indicated in system boundaries, study is newly includin: pretreatment process of carpets placed in Aquafi lusa fi shin nets pretreatment carried out by one of the waste suppliers newly implemented pretreatment step in Aquafi lslo, which enables better separation of input waste components Hazardous waste quantity is increased due to new waste fl ow in pretreatment process, which is linked to recyclin. Water consumption has increased as well, due to improved primary data quality. 15

17 EPD for Aquafil ECONYL ADDITIONAL INFORMATION 16

18 EPD for Aquafil ECONYL ADDITIONAL INFORMATION Additional information This chapter is intended to provide specific additional information about the ECONYL Reeneration System as well as some comments of its environmental added value. In 2009 we set ourselves the challene of collectin waste material all over the world and turnin it into recycled polymers. It is possible to mention other environmental benefits, besides those appreciated from the impact cateories investiated in the present study. As a matter of fact part of virin raw materials extraction and natural resources exploitation is prevented by the use of waste otherwise disposed off. The European Commission has estimated that the EU discards 5.8 million tonnes of textiles and apparel every year, 75% of this is sent to landfill or incinerated, but the vast bulk is destined for landfill. The USA enerates 12.7 million tonnes of textile waste; of this only 14.9% is recycled (US Environmental Protection Aency, 2009, which means more than 85% is waste, aain larely bein sent to landfill). To put this number in context, in 2009 a total of 71.6 million tonnes of fibre was used around the world. This means that the EU and the USA in one year alone discarded 18.5 million tonnes = 26% of annual lobal fibre usae. Another aspect not directly emerin from the present study, which is worth a mention, is the contribution to the prevention of oceans pollution from the collection of fishin nets in their endoflife. 17

19 EPD for Aquafil ECONYL REFERENCES References This declaration and further information about it are available at > Specific requirements The calculation of the environmental impact of the product was conducted accordin to the eneral EPD requirements. > Contacts To et more information about this environmental declaration or about Aquafil activities please contact: Lucija Aleksić T (0) > Independent verification CPC263 & 264/PCR2013:12 vers Independent verification of the declaration and data, accordin to ISO 14025: INTERNAL X EXTERNAL Third party verifier: Bureau Veritas, accredited by SWEDAC Valid until: 28. Auust