Life Cycle Assessment ofCarpet Products

May 12th , 2005CARE 3rd Annual Conference

Dr. Matthew J. RealffChemical & Biomolecular Engineering

Georgia TechDr. Michael Overcash and Mr. Yong LiChemical & Biomolecular Engineering

North Carolina State University

ADVANCED ENVIRONMENTAL FRAMEWORKS

• SUSTAINABILITY

• INDUSTRIAL ECOLOGY

• GREEN CHEMISTRY AND GREEN ENGINEERING PRINCIPLES

LIFE CYCLE IS THE PRINCIPLE TOOL OF ADVANCED ENVIRONMENTAL FRAMEWORKS

• IT IS THE QUANTIFICATION MECHANISM

• IT ENGENDERS IDEAS OF LIFE CYCLE THINKING

• IT IS EMERGING

OVERVIEW OF RATIONALE FOR USE OF LIFE CYCLE

1. To establish leadership in a demanding, emerging framework for environmental policy

2. To quantify environmental input to engineering, materials, and product innovations

3. To explore new advantages from evolving global environmental expectations

4. To create parallel information to Cost Of Ownership analyses.

Life cycle is a tool or technology, such as• Six Sigma• Statistical Quality Control

Increasingly used in a variety of product, process, and corporate issues in which environmental improvement is being made.

Referred to as an advanced environmental framework

ISSUES IN WHICH LIFE CYCLE PLAYS A SUBSTANTIAL ROLE

1) Green purchasing2) Beneficial reuse options, both internally and

externally3) International labeling or US rating systems4) Demand for recycle content from consumers5) Corporate sustainability policies6) CO2 (or other emissions) trading credits7) Challenges of landfill shortages over the long

term8) European and Japanese government initiatives

to require full life cycle responsibilities

Natural Resources

Raw MaterialAcquisition

UsePhase

Product Manufacturing

Product End-of-Life Management (PELM)

LIFE CYCLE BOUNDARIES

ASSESSMENT ACROSS A SYSTEM – REFERRED TO AS A BOUNDARY

LIFE CYCLE TOOLS

•POLICY ISSUES•SUSTAINABILITY•MACRO

IMPROVEMENTS

DECISIONSLIFE CYCLE STAGE

IMPROVEMENT ANALYSIS

IMPACT ASSESSMENT

INVENTORY ANALYSIS

•NEWTECHNOLOGY

•POLLUTIONPREVENTION

•PROCESS ALTERNATIVES

A LIFE CYCLE INVENTORY (LCI) IS A COMPLETE MASS AND ENERGY

BALANCE TO DETERMINE

• INPUTS

• CHEMICAL EMISSIONS

• ENERGY NEEDS

SOME BOUNDARY MUST BE SPECIFIED

LIFE CYCLE INVENTORY QUALITY

• TRANSPARENCY

• ENGINEERING PRINCIPLES OF MASS & ENERGY

• MULTIPLE VIEWS

• LOGICAL MECHANISM TO CHANGE

• EXPECTATIONS OF DECISION-MAKERS

• CRITICAL RELATION OF SYSTEM TO SUSTAINABILITY FACTORS

LCA CCACTI PROJECT STRUCTURE

• BUILD LIFE CYCLE INVENTORIES (MASS AND ENERGY) OF AT LEAST THREE REPRESENTATIVE CARPETS

– FRAMEWORK FOR ADDITIONAL STUDIES BY OTHERS (EXAMPLE: EFFECT OF PIGMENTS)

– MAJOR BASE FOR ADDITIONAL STUDIES FOR OTHER CARPET LIFE CYCLE STUDIES

– EMPHASIS ON TRANSPARENCY TO FACILITATE CHANGE– EMPHASIS ON MODULARITY TO FACILITATE REUSE OF

RESULTS

• EXPLORE ALL FOUR AREAS OF A FULL LIFE CYCLE– SUPPLY CHAIN– CARPET MANUFACTURING– USE CYCLES– PRODUCT-END-OF-LIFE TECHNOLOGIES

• COMMITMENT TO OPEN ACCESS FOR LCI DATA (THE GATE-TO-GATE BLOCKS)

CarpetManufacturing

Life Cycle Scope & Changing Impacts

CarpetManufacturing

Carpet MaterialSupply Chain

Natural or Mineral Resources

Carpet Raw Materials (e.g. latex)

EnergyMaterials Wastes

Disposal

CarpetRecycling

CarpetManufacturing

Carpet MaterialSupply Chain

Recycled materials

Disposal

LCA Boundary

Use Phase

OPEN ACCESS DATABASE

UNRESTRICTED USE IS ALLOWED ONLY WITH THE FOLLOWING CITATION FOR EACH AND EVERY TIME USED.

(OVERCASH 1998 – 2004)

Overcash, M. Lci gate-to-gate database, Department of Chemical and Biomolecular Engineering, NCSU, Raleigh, NC, 1998 - 2004

Overall Objective in Rationalizing Comparisons

• Enable Industry to Focus on the distinctions that CAN be made with reasonable LCI calculations.

• Enable Focus on the distinctions that are a function of carpet manufacturing and choice of raw materials NOT differences in LCI assumptions.

• Enable Focus on the BIGGEST impacts of changing construction, manufacturing and materials.

Life Cycle Indicator 1

Life Cycle Indicator 2

Group of Carpets with similar impact

Carpets with less impact

Carpets with different impact

Overall Objective in Rationalization of Comparisons

Gate-to-Gate LCI Example

Hexamethylene Diamine

Materials & Energy Specific Material or Product

Manufacturing Process

Executive SummaryHexamethylenediamineContents of Factory Gate to Factory Gate

Life Cycle Inventory Summary

ChemistryNet Desired Reaction:

2622242 )(4)( NHCHNHHCNCHNC →+Adiponitrile Hydrogen HexamethylenediamineSide Reactions:

362242 )(4)( NHNHCHHCNCHNC +→+

Adiponitrile Hydrogen Hexamethyleneimine Ammonia

3262622242 )()(8)(2 NHNHCHNHCHNHHCNCHNC +→+Adiponitrile Hydrogen Bishexamethylenetriamine Ammonia

Product: HexamethylenediamineBasis: 1000 kg/h hexamethylenediamineReferences: Kirk-Othmer Encyclopedia of Chemical Technology. 4th edition,

John Wiley & Sons, New York, USA, 1992Plant Location:Comments: Values for mass and energy flows per hour are equivalent to mass or

energy flows per 1000 kg of product.Allocation: Mass basis (Factor = 0.905)

kg/h1072.961Total

kg/h0Process Water

kg/h11.40581Ammonia

kg/h70.33584Hydrogen

kg/h991.2193Adiponitrile

CommentsUnitsAmountsChemical

Product:

>99% purekg/h1000Hexamethylenediamine

CommentsUnitsAmountChemical

Inputs:

Process Emissions:

kg/h-1Mass Balance Difference

kg/h3.53Hydrogen

kg/h49.52Adiponitrile

kg/h19.55Ammonia

SolventSolidLiquidAir

CommentsUnitsAmountsChemical

Energy Requirements:

1775.668Net Energy

-1327.06Potential Energy/Electricity Recovery

-3619.08Cooling Water

2178.275Heating-Steam

MJ/h924.2328Electricity

CommentsUnitsAmountSource

H2 (g)

CN(CH2 )4CN (l)

A

D

C

Process Diagram for the Hydrogenation of Adiponitrile to Hexamethylenediamine

77.7 kg

1095 kg

Compressor 1

Mixer with Jacket 1

1 (g)

4 (l )

25°C, 600 atm

3 (l )

5 (g)

5a (g)

19a (g )

22 (g )

25°C

140°C

100°C

25°C

135°C

100°C

Pump 2 BHeater 1 4a (l )

Pump 4

2 (g)

S 1 (g)

S 2 (l)207°C

207°C

120°C, 600 atm

600 atm

C 3

C 1C 2

Cooler 2

20°C

50°C

20°C

150°C

600 atm

1 atm

1 atm

600 atm

600 atm

600 atm

Assumption

All streams are at 1atm and 25°C if not stated otherwise.

S 3 (g) S 4 (l)207°C207°C

600 atm699.4 kg H2

673.4 kg NH3

3641 kg NH3

777 kg H24314 kg NH3

1095 kg CN(CH2 )4CN (l)

938.2 kg

938.2 kg

938.2 kg

91 kg

91 kg

459.3 kg459.3 kg

C 31, 20ºC

6590 kg

C 32, 20ºC

6590 kg

C 33, 50ºC

6590 kg

Pump 22

Abbreviations of compounds

Reactor

H2 +NH3

C

D

A

Liquid NH3

H2 (g) +NH3 (v)

E

Make-up valve

Ammonia (l )

Pump 6C

ondenser1

Pump 5

Separator

5a (g)

6 (l )

C 4

20 °C

C 5

20 °C

C 6

50 °C

17 (g )

18 (l+g )

20 (l )

19a (g )

23 (l )

22 (l ) 100°C 21 (l ) 100°C

25°C

100°C, 600 atm

,150°C,600 atm

100°C

100°C

600 atm150°C,

600 atm

150°C

135°C, 600 atm7 (l )

150°C, 1 atm

B

12.6 kg NH3, 9.9 atm

4a (l)

120°C, 600 atm

699.4 kg H2, 673.4 kg NH3

3654 kgNH3

3641 kg NH3

4327 kg NH3, 699.4 kg H2

1000 kg HMDA, 50.2 kgHMI

54.5 kg BisHMTA

54.7 kg ADN 1095 kg ADN

777 kg H2, 4314 kg NH3

AND= adiponitrile

HMDA= hexamethylenediamine

HMTA=bishexamethylenetriamine

HMI= hexamethyleneimine

600 atm

600 atm

600 atm

Turbine 1

Compressor 2

19 (g)100°C, 600 atm

600 atm

1000 kg HMDA, 50.2 kgHMI

54.5 kg BisHMTA

54.7 kg ADN

8290 kg

8290 kg

8290 kgPump 23

Heater 2

24 (l )25 (l ), 12.6 kg NH3 25°C, 600 atm

100°C, 600 atm

S12 (l) 207°CS 11 (g)207°C

C 37

20 °C6736 kg Pump 25

C 3820 °C6736 kg

C 3920 °C6736 kg

Still bottoms waste :Adiponitrile 54.7 kg

Hexamethylene-diamine 1000 kg

E7 (l )

8 (l )

9 (l )

10 (l )

11 ( s )

Crystallizer

Cooler 3

Pump 15

Pump 11

Pump 12

Pump 14

Distillation C

olumn 1

Distillation C

olumn 2

C 7

20 °C

C 8

20 °C

C 950 °C

C 10

20 °C

C 11

20 °CC 12

50 °C

S 6 (l)

207 °C

S 5 (g)

207 °C

C 34

20 °C

S 8 (l)

207 °C

S 7 (g)

207 °C

C 18

50 °C

C17 275.8 kg

20 °C

C 14

20 °C

C 13

20 °C

C 15

50 °C

Condenser 2

12 (l )

15 (l+v )

16 (l ),

165°C

150°C

1 atm25°C

25°C, 1atm

100°C

205°C

205°C

165°C

Cooler 1

1 atm

135°C

13 (l )

50 °C

1 atm

Assume that the crystallizer is 100 % efficient

C 19

C 20

C 21

205 °C

20 °C

20 °C

165°C

8a (l )

9a (l )205°C

14 (l )

15a (l+v )165°C

Pump 7

Pump 8

Pump 9

Pump 10

Pump 13

1000 kg HMDA

54.5 kg BisHMTA

54.7 kg AND, 50.2 kg HMI

Volatile waste:104.7 kg

1054.7 kg product

1862kg

1862kg

1862kg

74.5kg74.5kg 131.5 kg

131.5kg

131.5kg

275.8kg

822.8kg

2600 kg

8393kg

822.8kg

822.8kg

8393kg8393kg

599.7kg 599.7kg,

F

1000 kg HMDA

54.7 ADN kg

C 3650°C2600 kg

C 3520°C2600 kg

C 1620 °C

275.8kg

Pump 24

F

Cooler 4

Cooler 5

Distillation 3

Pump 16

Pump 17

Pump 20

Pump 18

Pump 19

Pump 21

16a (l )16 (l )

16b (l )16c (l )

16f (l )16e (l )

16d (l )

16g (l )

C 26

C 23

C 24

C 22

C 25

C 27

C 28C 29

C 30

S 9 (g)

S 10 (l)

,1 atm

138°C

135°C135°C

207°C

207°C

138°C

20°C

50°C

20°C

25°C

50°C

20°C20°C

20°C

138°C138°C

20°C

50°C

25°C

,1 atm

HMI=Hexamethyleneimine

HMTA=Bishexamethylenetriamine

HMTA 54.5 kg

HMI 50.2 kg

32.1 kg

32.1 kg

141 kg141 kg

141 kg

110 kg

110 kg110 kg482.1 kg

482.1 kg482.1 kg

HMI 50.2 kgHMTA 54.5 kg

HMTA 54.5 kg

HMI 50.2 kg

-1465.52Total:2039.44121.00Dist. Reb. 1

-3.76138.00-3398.30-15.03Cooler 51918.440.00Pump 12

-2.93138.00-3383.28-11.73Cooler 41918.434.96Heater 2

-12.85138.00-3371.55-51.39Dist. Cond. 31913.4873.09Pump 23

-13.23165.00-3320.16-29.40Condenser 21840.390.04Pump 6

-427.86150.00-3290.76-950.80Condenser 11840.350.00Comp 2

-6.31205.00-2339.96-14.02Cooler 11840.350.26Pump 5

-69.30100.00-2325.94-277.20Crystallizer1840.090.12Pump 25

-89.30205.00-2048.74-198.45Cooler 31839.970.09Pump 4

-402.57205.00-1850.29-894.59Dist.Cond. 21839.88745.80Mixer

-39.47165.00-955.70-87.70Dist. Cond. 1 1094.080.08Pump 22

-49.80NA-868.00-49.80Turbine 11093.99840.00Comp 1

-323.10150.00-818.20-718.00Reactor253.99147.82Heater 1

-25.05140.00-100.20-100.20Cooler 2 106.17106.17Pump 2

Potential Energy Recovery

Index Temp. of Stream Cooled (°C)

CumulativeEnergy LossUnit OperationCumulativeEnergy InputUnit Operation

Energy Recovery (MJ/hr)Energy Input (MJ/hr)

Energy Input and Recovery Summary

3065.8052.11Dist.Reb. 3

3013.690.00Pump 16

3013.690.00Pump 14

3013.690.00Pump 13

3013.690.11Pump 24

3013.580.10Pump 15

3013.490.09Pump 8

3013.400.09Pump 10

3013.310.09Pump 9

3013.22973.70Dist. Reb. 2

2039.520.00Pump 11

2039.520.09Pump 7

1600.63Total Energy

-1465.52Heat Recovery

3066.150.08Pump 20

3066.060.09Pump 19

3065.980.00Pump 21

3065.970.09Pump 18

3065.890.09Pump 17

Cumulative Energy Input

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

3500.00P

ump

2

Hea

ter 1

Com

p 1

Pum

p 22

Mix

er

Pum

p 4

Pum

p 25

Pum

p 5

Com

p 2

Pum

p 6

Pum

p 23

Hea

ter

2

Pum

p 12

Dis

t. R

eb. 1

Pum

p 7

Pum

p 11

Dis

t. R

eb. 2

Pum

p 9

Pum

p 10

Pum

p 8

Pum

p 15

Pum

p 24

Pum

p 13

Pum

p 14

Pum

p 16

Dis

t.Reb

. 3

Pum

p 17

Pum

p 18

Pum

p 21

Pum

p 19

Pum

p 20

Hea

t Rec

over

y

Process Unit

MJ/

1000

kg P

rod

uct

FOR THOSE WHO HAVE USED OTHER LIFE CYCLE DATABASES, SUCH AS Boustead, BEES, Franklin Associates,

YOU CAN SEE IN THIS PROJECT WE HAVE TAKEN A DIFFERENT APPROACH AND LEVEL TO TRANSPARENCY

Major Components of Representative PVC back tile carpet 2004

Chemical name CAS no.nylon6 or nylon66 (20 oz) 25038-54-4 or 32131-17-2 0.567 13.7%Polyethylene terephthalate, PET 25038-59-9 0.113 2.7%diisoheptyl phthalate 71888-89-6 0.536 13.0%Ethylene-vinyl Acetate Copolymer 0.192 4.7%Calcium carbonate 1317-65-3 1.957 47.4%Ethene, chlorohomopolymer 0.14 3.4%poly(Ethylacrylate-co-vinyl chloride) 25035-97-6 0.429 10.4%Additives 0.19 4.6%

Total 4.124 100%

Mass and composition

Additives of Representative PVC back tile carpet 2004

Chemical name CAS no.

Sb2O3 Antimony trioxide 1309-64-4ammonia 7664-41-7carbon black 1333-86-4Anionic surfactantAnionic Surface modifierHydrous Aluminum Silicate 1332-58-7sodium polyacrylate copolymer solution 25987-30-8DGF-30 Stainblocker 1Fiber glass 65997-17-3FX-668 Stainblocker 2Ethene, chloro-homopolymer 9002-86-2n-Paraffinic Hydrocarbon 64771-72-8Sodium Dodecylbenzenesulfonate 251-55-300Soy phosphalipids 8002-43-5Calcium oxide 1305-78-8methylenebisthiocyanate 6317-18-6Sodium Polyacrylate 9003--04--7PVC stabilizer Trade secret # 80100455-101TG-3360 fluorocarbonzinc pyridinethione C10H8N2O2S2Zn 13463-41-7

Major Components of Representative SBR Latex Broadloom Carpet 2004

Materials Mass, kg/syAluminum hydroxide 0.386CaCO3 0.386Styrene butadiene rubber 0.18Polypropylene 0.199Nylon 6/66 (28 oz) 0.794Additives 1.43E-02

Total 1.96

Ammonia, (Aqua Amonia)Anionic surfactantAntimony TrioxideAnionic surface modifierDGF-30 stainblocker 1FX-668 stainblocker 2methylenebisthiocyanateSodium Dodecylbenzenesulfonate

sodium polyacrylate copolymerSodium PolyacrylateTG-3360 fluorocarbonZinc Omadine

Partial List of Additives in Representative SBR Latex Broadloom Carpet 2004

Representative PVC backed tile carpet production 2004

Mechanical Mixing 2

A2

2 (l)

25 oC

A12a (l)

25 oC

2b (l)

25 oC

2.6649 kg PVC Plastisol

PVC Plastisol components

1 (l)

25 oC

Materials Mass, kg/sy

Diisoheptyl phthalate 0.54

poly(Ethylacrylate-co-vinyl chloride) 0.43

Ethene, chloro-homopolymer 0.14CaCO3 1.43

Additives 0.13Total 2.66

Major component

0.1134kg/sy Polyester backing

Steamer

0.567kg/syDyed nylon 6

3 (s)

25 oC 7 (s)

30 oC

4 (s)

25 oC

Dryer 1

0.0142 kg/sy H2O

8(l)

25 oC

10(g)

100 o C

0.5867 kg/sy

Steam

Twisting &Warping

5 (s)

25 oC

Tufting

11 (s)

70 oC

15 (g)

100 o C

Room cooling

12 (s)

40 oC

Hot water

0.5725 kg/sy

11a (l)

100 o C

B16 (s)

40 oC

7a (l)

31 oC

Solid Waste

1.50e -3 kg/sy

83.3% nylon

16.7% Polyester

Representative PVC backed tile carpet production 2004

Stainblocker, 9.64e -3 kg/sy

C

16 (s)

40 oC

Precoater

Mechanical mixing 1

18 (l)

25 oC

Water, 0.491 kg/hrLatex, 0.737 kg/sy

17 (l)

25 oC

Dryer 2

21 (g)

180 o C

Hot air

2.5 kg/sy

20(g)

180 o C

Blw 1

0.01416 kg/sy H2O

2.5 kg/sy Air

19 (s)

30 oC

22 (g)

23 (s)

110 o C

P11a

C1, 15 oC4.8 kg/sy

C2,20 oC

Chill rolls 1Drum 1

Room cooling

24 (s)

100 o C

25 (s)

45 oC

P11b

C4,20 oC

Chill rolls 1Drum 2

24b (s)

50 oC

Room cooling

24a (s)

80 oC

C3,15o C

Solid Waste

3.54e-3 kg/sy

Water

0.477 kg/sy

B

19a (s)

30 oC

Representative PVC backed tile carpet production 2004

4.8 kg/sy

0.4 kg/sy

0.4 kg/sy 50 oC

Material Dry Weight (oz/sy)

Ethylene-vinyl Acetate Copolymer, (99808) 0.192357Antimony Trioxide 0.009581CaCO3, (D-70) 0.528429

Additives Additives 0.006633

Major component

Latex components

Tile Cutting

Packaging

Trim waste0.0942 kg/sy

0.0425 kg/sy Fiberglass scrim

1 square yard Packaged carpet

(3.97 kg/sy)

Cardboard boxesHot melt glueWood palletsStretch wrap

C

A1

35 (s)

70 oC

28 (s)

39 (s)

25 oC

Coating 1

Chill rolls 2

27 (s) 32 (s)

36 (s)

38 (s)

25 oC

40 (s)

25 oC

50 ºC

A2

33 (s)

2b (l)

25 oC

37 (s)

25 oC

2a (l)

25 oC

Coating 2

Air11.9 kg/sy

30 (g)

25 oC

31 (g)

50 ºC

Oven 2Oven 1

150 ºC 100 ºCAir Cooler

60 ºC50 ºC30 ºC

25 (s)

45 oC

26 (s)

25 oC

29 (g)

25 oC

C5

16 oC

C6

23 oC

Blw 2

P12

Room Cooling

34 (s)

32a (s)

25 ºC

Waste6.81e-2 kg/sy

Representative PVC backed tile carpet production, 2004

3.8 kg/sy

3.8 kg/sy

Air11.9 kg/sy

List of all additives in PVC tile process

Sb2O3 Antimony trioxideammoniacarbon blackAnionic surfactantAnionic Surface modifierHydrous Aluminum Silicatesodium polyacrylate copolymer solutionStainblocker 1Fiber glassStainblocker 2n-Paraffinic HydrocarbonSodium DodecylbenzenesulfonateSoy phospholipidsCalcium oxidemethylenebisthiocyanate Sodium PolyacrylatePVC stabilizerFluorochemicalzinc pyridinethione C10H8N2O2S2Zn

0.086 kg/syPolypropylene backing

Tufting

Stain and soil resistance application

0.794 kg/syDyed nylon 6

1 (s) 2 (s)

3 (s)

4 (s)

Twisting& Warping

Nip rollers 1

Representative SBR backed broadloom carpet production, 2004

A

7 (s)

Nip rollers 2

Dryer 1

10 (s)

0.5867 kg/sy H2O

0.01417 kg/syH2O

9 (g)

2 x 10-4 lb Stain and soil resistance coating

5 (s)

8 (s)

25 oC 25 oC

25 oC

25 oC 25 oC

25 oC

100 o C

0.445 kg/sy H2O

100 oC

6 (l)

100 o C

6a (g)

6b (l) 50 oC

25 oC

150 o C

Carpet waste,2.29e -3, kg/sy

3a (s)

25 oC

R1

0.96 kg/sySBR Latex

Compounding

0.82 kg/syWater

11 (l)

0.113 kg/sySecondary polypropylene backing

Lick roller 2

A

16 (s)

Adhesive applicator

15 (l) 17 (s)

18 (s)

0.17 kg/syLatex adhesive

0.79 kg/syLatex adhesive

B

Secondary backing application

10 (s)

13 (l) 14 (l)

19 (s)

Representative SBR backed broadloom carpet production, 2004

25 oC

150 o C

25 oC 25 oC

25 oC

25 oC

25 oC

25 oC

25 oC

Latex major component

SBR 0.18Aluminum hydroxide 0.39CaCO3 0.39Additives 1.4E-02

Total 0.96

18b (s)

25 oC

Carpet waste with secondary backing, 2.77e -2, kg/sy

Finishing

Packaging

Inspection &

Warranty return

Inspection and Warranty returns, 3.85e -2 kg/sy

1 square yard Finished carpet, (1.88 kg/sy)

25 (s)

24 (s)

26 (s)

Representative SBR backed broadloom carpet production, 2004

Dryer 2 23 (s)

20 (s)19 (s)

177 °C

157 °C

150 °C

60 °C

Air Cooler

Air, 11.1 kg/sy

21 (g)

22 (g)B

25 °C

25 °C

25 °C

50 °C

25 °C

19a (g)

H2O, 0.82 kg/sy

150 °C

25 °C Air, 11.1 kg/sy

List of additives in SBR carpet process

Ammonia, (Aqua Amonia)Anionic surfactantAntimony TrioxideAnionic Surface modifierStainblocker1Stainblocker2methylenebisthiocyanateSodium Dodecylbenzenesulfonatesodium polyacrylate copolymerSodium PolyacrylateFluorochemicalZinc Omadine

Ref

eren

ce

Uni

t

Ene

rgy

inpu

t [K

J / sy

]

Cum

ulat

ive

ener

gy K

J /

sy]

Ene

rgy

Typ

e

Uni

t

Ene

rgy

Loss

Cum

ulat

ive

ener

gy lo

ss

Invista Twisting 62.1 62.1 E Chilled rolls 1 drum 1 47.4 47.4Invista Twisting 761.0 823.1 F Chilled rolls 1 drum 2 6.4 53.9Shaw Warping 42.9 866.1 E Chilled rolls 2 106.4 160.3Shaw Tufting 832.3 1698.4 E Air cooler 300 50NCSU/Shaw Steamer 1191.8 2890.2 SNCSU/Shaw Dryer 1 177.0 3067.2 FNCSU/Shaw Mechanical mixing 1 22.3 3089.5 ENCSU/Shaw Dryer 2 3687.0 6776.5 FNCSU/Shaw Mechanical mixing 2 172.6 6949.1 ENCSU/Shaw Oven 1 1356.9 8306.0 FNCSU/Shaw Oven 2 923.5 9229.5 FShaw Tile cutting 245.3 9474.8 E

NCSU/ShawRefrigeration for Chilled rolls 1 Drum 1 2.6 9477.4 E

NCSU/ShawRefrigeration for Chilled rolls 1 Drum 2 0.2 9477.6 E

NCSU/Shaw Refrigeration for Chilled rolls 2 2.4 9480.0 EPotential recovery:

Electricity 1382.8 E 1.38E+03DowTherm 0.0 D 0.00E+00Heating steam 1191.8 S 1.40E+03Direct fuel use 6905.4 F 6.91E+03Energy input requirement 9480.0 9.69E+03Cooling waterCooling refrigeration* 160.3Potential heat recoveryNet energy 9480.0 PVC tile 2004

* Cooling refrigeration is the energy removed from the system by refrigeration, not input to refrigeration system

Cooling Requirements [kJ / sy]Energy Input [kJ / sy]

Type of waste Mass, kg/syPrimary backed tile waste 1.50E-03

Primary backed and precoated tile waste 3.54E-03

Primary and secondary backed tile waste 0.1623

List of waste in Representative PVC tile process 2004

Primary 1st 2nd 3rd 4th 5th 6th 7th Nylon 6 Caprolactam Cyclohexanone

oximeCyclohexanone Cyclohexane Benzene

Hydrogen

Oxygen AirOxygen

Hydroxylammonium sulfate (20.94% water solution) Hydrogen

Oxygen Nitrogen monoxide Ammonia

Oxygen

sulfuric acid Sulfur trioxide Sulfur Petroleum

extraction/refinery

Sulfuric acid Sulfur trioxide Sulfur

Ammonia

Sulfuric acid Sulfur trioxide Sulfur

Ammonia

Sulfur trioxide Sulfur

Benzene

Nitrogen

Air

Natural gas

Petroleum extraction/refinery

Natural gasAirAir

Natural gas

Water Air

AirWater

AirWater

AirPetroleum extraction/refinery

AirPetroleum extraction/refinery

WaterNatural gas

WaterNatural gas

AirWater

Air

Petroleum extraction/refinery

AirPetroleum extraction/refinery

Chemical Tree

Contributions of each gate-to-gate Life Cycle Inventory to overall product LCI

Product Manufacture

GTG energy of chemicals on nylon6 CTG chemistry tree

-15.0

-10.0

-5.0

0.0

5.0

10.0

15.0

20.0

Nyl

on

6

Am

mo

nia

Pet

role

um

extr

acti

on

/ref

iner

y

Su

lfu

r

Nat

ura

l gas

Ben

zen

e

Nit

rog

en

Oxy

gen

Hyd

rog

en

Cap

rola

ctam

Cyc

loh

exan

on

e

Cyc

loh

exan

on

eo

xim

e

Su

lfu

ric

acid

wat

er

Hyd

roxy

lam

mo

niu

msu

lfat

e (2

0.94

%w

ater

so

luti

on

)

Su

lfu

r tr

ioxi

de

Cyc

loh

exan

e

Chemicals

GT

G e

ner

gy,

MJ/

kg c

hem

ical

. .

NO

GTG energy of chemicals on the nylon66 chemistry tree

-5

0

5

10

15

20

25

30

35

40

Adi

pic

Aci

d

Adi

poni

trile

Nyl

on6-

6P

etro

leum

extra

ctio

n/re

finer

yP

ropy

lene

Cyc

lohe

xano

l

Nat

ural

gas

NaO

H

Sul

fur

Hex

amet

hyle

nedi

amin

e

Oxy

gen

Cyc

lohe

xano

ne

H2S

O4

Cyc

lohe

xane

Sod

ium

chl

orid

e

Ben

zene

Am

mon

ia

Hyd

roge

n

Wat

er

Sul

fur t

rioxi

de

Nitr

ic a

cid

Chemicals

GTG

ene

rgy

of c

hem

ical

s, M

J/kg

. .

.

Acr

ylon

itrile

Energy on CTG chemistry tree of nylon 6

-202468

10121416

Nyl

on 6

Cap

rola

ctam

Nitr

ogen

Cyc

lohe

xano

ne o

xim

e

Sul

furic

aci

d

Am

mon

ia

Sul

fur

triox

ide

Ben

zene

Cyc

lohe

xano

ne

Hyd

roxy

lam

mon

ium

sul

fate

(20

.94%

wat

er s

olut

ion)

Sul

furic

aci

d

Am

mon

ia

Sul

fur

triox

ide

Sul

fur

Cyc

lohe

xane

Oxy

gen

Hyd

roge

n

Nitr

ogen

mon

oxid

e

Sul

furic

aci

d

Sul

fur

triox

ide

Sul

fur

Ben

zene

Hyd

roge

n

Oxy

gen

Am

mon

ia

Sul

fur

triox

ide

Sul

fur

Oxy

gen

Sul

fur

Nat

ural

gas

Pet

role

um e

xtra

ctio

n/re

finer

y

wat

er

Chemicals

En

erg

y o

n th

e C

TG

ch

emis

try

tree

, MJ/

kg n

ylo

n6

. .

Pro

duct

1stst

age

2nd

stag

e

3rd

stag

e

4th

stag

e

Nat

ural

res

ourc

e

5th

stag

e

6th

stag

e

Energy on the chemistry tree of nylon 66

-5.00

0.00

5.00

10.00

15.00

20.00

25.00N

ylon

6-6

Adi

pic

Aci

dH

exam

ethy

lene

diam

ine

Cyc

lohe

xano

neC

yclo

hexa

nol

Nitr

ic a

cid

Adi

poni

trile

Am

mon

iaH

ydro

gen

Cyc

lohe

xane

Oxy

gen

Am

mon

iaA

cryl

onitr

ileO

xyge

n

Ben

zene

H

ydro

gen

Pro

pyle

neA

mm

onia

Oxy

gen

H2S

O4

NaO

H

Oxy

gen

Sul

fur

trio

xide

Sod

ium

chl

orid

e

Sul

fur

Nat

ural

gas

Pet

role

umW

ater

Chemical on the CTG chemistry of nylon66

Ene

rgy

on t

he C

TG t

ree,

MJ/

kg n

ylon

66

..

Pro

duct

2nd

stag

e

3rd

stag

e

4th

stag

e

Nat

ural

res

ourc

e

5th

stag

e

6th

stag

e

1stst

age

Nylon66 and nylon6 energy comparison

-8.0

0.0

8.0

16.0

24.0Nylon product

1st

2nd

3rd

4th

5th

6th

Raw materials

Nylon66Nylon6

NYLON COMPARISONS

BOUSTEAD (EUROPEAN)• CRADLE-TO-GATE

– 6,6 93 MJ/kg (+15%)– 6 81 MJ/kg

DOE – OIT (U.S.)• CRADLE-TO-GATE

– 6,6 76 MJ/kg (+17%)– 6 65 MK/kg

CALCIUM CARBONATE

Quarry/grinding

method

Heat/precipitation

method

Energy, MJ/kg 4.7

Chemical losses, kg/kg 0.135

0.18

0.075

Pigments/Dyes and LCI

Selection Criteria§ Variation in categories of hazard classification§ Large use in commercial carpet§ Comparison to pigments

Suggested Dyes• Benign Acid Blue 277• Low – moderate Acid Blue 324• Above moderate Acid Orange 156

Transportation Module

Representative Transportation Logistics to be considered in LifeCycle Assessment:

•Transportation of Raw Materials

•Face Fiber

•Latex or other backing materials

•Calcium Carbonate

•Transportation of Final Product

•Transportation of Recycled Product or Material

What distances?What Modes of Transport?

Generic Module: <Mode|Distance|Material Type|Load Quantity>

End Of Life Project •Evaluation of carpet as a fuel (Mass, Energy and Emissions

Impacts) with coal displacement.

•Develop Generic Modules that will allow connection of forward and reverse manufacturing systems.

•Based on named materials used in manufacturing.

•Based on named materials produced during recycling.

Forward Manufacturing Process

Recycling Manufacturing Process

monomer fillerpolymer

Overall Recycling System Modules

Forward Production System

Local Collection

Sorting Transportation

Recycling Process

Recycling Collection ModuleLocal Transportation (Specialization of Generic Transport)

Sorting Process

Unsorted Carpet

Sorted Carpet Fractions

<{Types}, {(Type | %Yield), (Type | %Yield), …}

<Mode |Distance |Unsorted Carpet |Load Quantity>

Recycling Process Module

Material Fractions Created by Recycling

Face Fiber

Backing Polymer

Filler

UnspunFace Fiber

Uncompounded Backing Polymer

Uncompounded Filler

Material Types Required in Production

(45%|25%)

(75%|50%)

(5%|10%)

(55%|50%)

<{Material1}, {Material2}, {(%Yield of Material1|% Reuse in Material2)}>

Energy

Aux.Materials

End Of Life Options

Landfill

Cement Kiln

Alternative Fuel

Raw Material Recovery

Supply Chain Material Recovery

Volume

•Emissions

•Emissions•Ash Landfill

•Energy•Aux. Materials

•Landfill•Emission

•Material & Energy Consumption

End of Life Option Impact Avoided Impact

PROJECT MILESTONES FOR YEAR 1 (accessible gtg information)

•Two representative carpet gate-to-gates (~75%)

• Nylon (6 & 6,6) (~90%, without additives/dyes)

• Other major constituents (~40%)

• Use phase (~60%)

• Product end-of-life technologies scheduled for years 2 and 3

CONTINUING TASKS

• ESTABLISH PROCESS FOR INDUSTRY REVIEW (regular meetings)

• BEGIN DISSEMINATION OF LCI BLOCKS TO INDUSTRY MEMBERS (open use with citation)

• PROGRESS ON REPRESENTATIVE CARPET LIFE CYCLE PROFILES

• ADD POLYURETHANE BROADLOOM

• MOVE FORWARD ON END-OF-LIFE PHASE

• IDENTIFY ISSUES FOR USE IN STANDARDS (CRI MEMBER INPUT)

• IDENTIFY OTHER TYPES OF MATERIALS TO INCLUDE– BIOBASED POLYMERS? (Polylactic Acid, Polytrimethylenetetraphthalate)

Summary

• Life Cycle Assessment is a key tool for environmental measurement and quantification.

• GIGO – Data quality and transparency is key to making the assessment defensible and reuseable.

• Confusion abounds (e.g. PVC) , life cycle will NOT solve this, weighting of impacts is crucial.