Symbol of TORAY’s environmental action Toray s Action for ...news.textiles.org.tw/2011sustainabilityforum/PPT/Session II/TITAS... · Toray’s Action for the Global Environment

13 October, 2011

Kouji SasakiGeneral Manager

Fibers＆Textiles Green Innovation

Business Planning Dept.

Toray Industries, Inc.

Toray’s Action for the Global Environment

ー To build a sustainable Low-Carbon Society ー

Symbol of Symbol of TORAYTORAY’’ssenvironmental actionenvironmental action

Copyright 2011 Toray Industries, Inc. All Rights Reserved. 1

contentscontents

Ⅰ．Toray’s Profile

Ⅱ．Toray’s Approach to Global Environmental Issues-Global Environmental Issues-New Era of Environment, Resource, Energy-What is LCM

Ⅲ. Toray’s Action for the Global Environment -Green Innovation products

・LCA-carbon fiber・Energy save-HEATTECH・Biomass-PLA , 3GT・Recycle

Ⅳ．Conclusion

Ⅴ．Message


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Ⅳ．Conclusion

Ⅴ．Message


Transition of TorayTransition of Toray’’s Business Fieldss Business Fields

Establishment1926

EstablishmentEstablishment19261926

1960 1970 1980 1990 2000 2010 1950

Sales Amount

〜〜

Rayon

Fibers & Textiles

Resins・Films

Toward a Top Level Global Company of Advanced MaterialsToward a Top Level Global Company of Advanced Materials

Globalization

High Performance Materials

IT-Related Products

Pharmaceutical &Medical Materials

Carbon FiberComposite Materials

Water Treatment Membranes

New Energy MaterialsEnergy-Saving MaterialsBiochemical Polymer

1. Established: 1926

2. Capital: 1.85bil US$

3. Number of Subsidiaries: 227

4. Number of Employees: 38,740



Net Sales by Segment in FY2010(Actual)

(￥82/US$)

Net Sales by Segmentin FY2010(Actual)

(38%)

(25%)

(17%)

(12%)

0.81 (4%)

0.82 (4%)

7.12

4.66

3.20

2.17

18.8 Bｉｌｌｉｏｎ US$Consolidated

＜Main Products ＞＜Business Segment＞

Bolster the foundation for revenue and profit through steady growth

Aggressively expand as drivers of revenue and profit growth

Develop as the next drivers of revenue and profit growth

Foundation Businesses

StrategicallyExpandingBusinesses

IntensivelyDeveloping

andExpanding Business

Fibers and Textiles

Plastics & Chemicals

IT-Related Products

Carbon FiberComposite Materials

Environment &Engineering

Life Science & others



MMediumedium--term management program term management program ““APAP--G 2013G 2013””


Expand businesses in growth business fields and regions

Establish a robust business footing by cost reductions

Key Principle

1.GreenGreen InnovationInnovation Business Expansion (GR) Project2.Asia and Emerging Country Business Expansion (AE) Project3.Total Cost Reduction (TC-II) Project

GroupGroup--wide Projects for thewide Projects for the Implementation of APImplementation of AP--G 2013G 2013


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Ⅳ．Conclusion

Ⅴ．Message


Global Environmental Issues

③③Depletion of Depletion of ResourcesResources

Resource Proven Reserves R/P Ratio

Oil1,188.6Gbarrel

(2004)40.5

Coal909.064Gt

(2004)164

Natural gas179Tm3(2004)

66.7

Uranium4.59Mt(2003)

85

Depletion of Natural Resource

05000100002000195019001850

②②Global Warming and COGlobal Warming and CO22 Emission IncreaseEmission Increase

Rising CO2 Conc.Increase of Average Temperature

Time(before 2005)

Increasing CO2 Emission

(Source：Climate Change 2007 Synthesis Report)

①①Economic Growth and Population ExplosionEconomic Growth and Population Explosion

Increasing World PopulationWater Shortage

(source:WMI report(2006))

Peak Oil

(Source：C.J.Campbell et al,ASPO(2004))

・Increasing Energy Consumption

・Water Shortage and Water Polution

・Food Shortage ‥‥

1900 Now 20301.6bil 6.5bil 8.5bilWorld Population

Energy Consumption0.4bton 9bton ≧17bton(as petroleum)

Ⅱ．Toray’s Approach to Global Environmental Issues


Sustainable Society based on non-fossil resources and renewable energy

Sustainable Society based on nonSustainable Society based on non--fossil resources fossil resources and renewable energy and renewable energy

①① Thermal power generation by coal/petroleumThermal power generation by coal/petroleum

②② Automobile fueled by GasolineAutomobile fueled by Gasoline

③③ Petrochemicals and polymersPetrochemicals and polymers

Mega-Consuming Society based on fossil fuel

The 20th

centuryThe 20th

century

The 21st

centuryThe 21st

century

①① Photovoltaic, Wind Power, Rechargeable BatteryPhotovoltaic, Wind Power, Rechargeable Battery

②② Electric VehicleElectric Vehicle

③③ BioBio--PolymersPolymers

New Era of Environment, Resource, Energy



economic growtheconomic growth

Ｔｏｒａｙ‘ｓｂａｓｉｃａｔｔｉｔｕｄｅ LCM（Life Cycle Management）

reducing environmental impact

reducing environmental impact

LCM is the idea of developing a business strategy for all corporate activities that takes into account the

environmental burden and cost in the entire lifecycle of a product or service with the aim to achieve sustainable

balance between reducing environmental burdens, while still promoting economic growth.


Compatible with each other

Sustainable growthSustainable growth


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Ⅳ．Conclusion

Ⅴ．Message


Energy Saving

New Energy Resources

Recycle

Biomass

Environmentally-friendly Products

Water Treatment

Air Purification

Measuresagainst

Global Warming

Reduction ofEnvironmental

Burdens

Bio-basedPolymer Products(Fibers, Plastics, Films)

Light and high strength Materials carbon fiberfor Automobile/Airplane

for Wind Power

Toray’ Advanced Materials

PolymerChemistry BiotechnologyOrganic synthetic

ChemistryToray Core Technology Nano-technology

Ⅲ.Toray’s Action for the Global EnvironmentSolution to Global Environmental Issues

- Green Innovation Products -

Green Innovation TechnologyFunctional textiles to reduce thermostat setting

Material or chemical recycle textiles for uniform

Heat resistant filter for air cleaning


Energy Saving


Recycle

Biomass

Environmentally-friendly Products

Water Treatment

Air Purification

Measuresagainst

Global Warming

Reduction ofEnvironmental

Burdens

Bio-basedPolymer Products(Fibers, Plastics, Films)

Light and high strength Materials carbon fiberfor Automobile/Airplane

for Wind Power

Toray’ Advanced Materials

PolymerChemistry BiotechnologyOrganic synthetic

ChemistryToray Core Technology Nano-technology

Ⅲ.Toray’s Action for the Global EnvironmentSolution to Global Environmental Issues

- Green Innovation Products -

Green Innovation TechnologyFunctional textiles to reduce thermostat setting

Material or chemical recycle textiles for uniform

Heat resistant filter for air cleaning

Secondly introduce three fiber’s environmentally-conscious products with

points of ecological appeal

At first we introduce carbon fiber’s contribution

to reduce CO2 emission


LCA (Life Cycle Assessment)-1

Emission of Environmental

Burden

A BC

Total

A+B+C+D

D

ＺＺ

Feedstock UseProduction Disposal

ＺＺ

Material miningTransportation

→Raw materials UseProduction disposal

LCA is a method to assess the environmental burdens and impact of our products through their entire life cycles.

GHG(CO2)、NOx、Sox、Toxic substance…

Sum of Environmental burden through its life

Ⅲ.Toray’s Action for the Global Environment


LCA-2

【Ａｉｒｃｒａｆｔ】 1% 99%

【Ａｕｔｏｍｏｂｉｌｅ】 83% 2%

Disposal stage

For reducing the total ＣＯ２ emission globally, both Use stage and Production stage

should be considered

LCA approach is the most effective method

16%

LCAexisting

technology

CO2 emission by sectorin 2008

Industry (420)Ind. Process (51)

Transport (236)Residential (172)Others (232)

Energy convert(78)Disposal (28)

Total：1217

production471

（39%）

Use640

（53%）

Others106

（9%）

＜Unit: Mton＞

Conventional car

Usestage

Productionstage



0

10

20

30

40

50

60

70

80

Conventional plane CFRP plane

Body w

eig

ht

（to

n）

OthersCFRPTiSteelAL

CFRP* Aircraft(*carbon fiber reinforced plastic)

（Based on material ratio of 787）

CFRP: 50% (24 ton)• Primary structures• Secondary structures

CFRP: 3% (1.8 ton)• Secondary structures

Boeing767-300

White Body Weight60→48ton (▲20%)

9% Reduction in Total Weight

Al

Steel

TiＣＦＲＰ

Body Fuel Payload

６０ｔ

４８ｔ１３ｔ

１３ｔ６１ｔ

６１ｔ

Conventional plane: 134 ton in total

CFRP plane:122 ton in total

Al

(JCMA: The Japan Carbon Fiber Manufacturers Association)

50% of Structures: CFRP Structure Weight: 20% Reduction

CFRP airplane model(same material ratio as Boeing787)

LCA example-carbon fiber (aircraft)

Conventional Aircraft

vsvs



原材料～製造

使用（10年）

組立廃棄

potential amount of CO2 emission reduction41 million ton／year

amount of ＣＯ2 emission reduction

27,000 ton ／ 1cargo・10years

+200 ▲800 ▲26,000 ▲２７,０００

materialassembly

flight(10years)

disposal＋＋＋

７００＋３,８００＋３９０,０００＋０＝

total＝

３９５,０００

９００＋３,０００＋３６４,０００＋０＝３６８,０００

<difference>

CO2emission

（ton/cargo）

Conventional plane

20%lightweight20%lightweightCFRP 50%

plane

2,700 ton-CO2/1year x 15,000 cargos ( over 100-seat aircraft )Convert to 1yearConvert to 1year

LCA example-carbon fiber (aircraft)



Energy saving-Warm inner cloth

Water vapor

Heat generationspace of micro acrylic

Heart retention

rayon

atypical cross-section

Quick dry＜＜Heat generationHeat generation＞＞■Rayon absorbs water vapor from human skin and the movement of the H2O molecule

creates kinetic energy that converts to thermal energy, thereby generating heat.＜＜Heat retentionHeat retention＞＞■Heat is maintained by the adiabatic effect that is made from air spaces between the

micro acrylic fibers. ＜＜Quick dryQuick dry＞＞■Atypical polyester that increase surface area by having a star shape absorbs and

diffuses water, while also alleviating the uncomfortable feeling of a wet skin surface.

Mechanism why it’s warm despite its thinness

skin

Appeal point : Energy saving by reducing thermostat settings Appeal point : Energy saving by reducing thermostat settings

Target : General Consumer Target : General Consumer



Energy saving-verification of HEATTECH’s effect

１．Verification of the effect on reduction thermostat setting Determine how many degrees Celsius the thermostat setting can be reduced by virtue of wearing HEATTECH through experiments that scientifically and quantitatively compare the effects* of HEATTECH with cotton inner cloth.(*Compared with cotton innerwear of the same shape and thickness)

１．Verification of the effect on reduction thermostat setting Determine how many degrees Celsius the thermostat setting can be reduced by virtue of wearing HEATTECH through experiments that scientifically and quantitatively compare the effects* of HEATTECH with cotton inner cloth.(*Compared with cotton innerwear of the same shape and thickness)

＜number of monitor＞８persons

measure degrees of room temperature when person’s temperature inside clothing is comfortable 30℃

measure degrees of room temperature when mannequin’s temperature inside clothing is comfortable 33℃(corresponds to 30℃ within the garment, a comfortable setting for human)

male ４、female ４ages 20～60

【conclusion】

・cotton ：１７.０ ℃

・HEATTECH ：１６.１ ℃

（２） Step 2: Experiment with thermal mannequin(to resolve the difference among individual subjects)

（１）Step1: Experiment with human subjects

Difference -１.０ ℃

・cotton ：１７.２ ℃

・HEATTECH : １６．２ ℃

Difference -0.9 ℃



0 25 50 75 100 125

綿インナー

ヒートテック

ＣＯ２排出量(kg-CO2eq／着・1シーズン)

製造

使用

処分

0.5

0.8 89 0.09

102 0.07

▲▲13kg13kg

0 25 50 75 100 125

綿インナー

ヒートテック

ＣＯ２排出量(kg-CO2eq／着・1シーズン)

製造

使用

処分

0.5

0.8 89 0.09

102 0.07

▲▲13kg13kg

Energy saving- HEATTECH LCA

1.0℃ reduction in thermostat settings

Impact on CO2 emissions during the product lifecycle*1

Manufacturing: +0.3 kg-CO2/garment per winter

Wear; -13 kg-CO2/garment per winter(due to lower thermostat temperature setting)

Disposal: +0.02 kg-CO2/garment per winter

CO２ reduction

13 kg-CO2per garment per winter

Effects of wearing HEATTECH (compared with cotton innerwear)

*1) Lifecycle: Total estimate including materials and manufacturing through to use and disposal

cottoncottonHEATTECHHEATTECH

ManufacturingManufacturingUsingUsingDisposalDisposal

CO2emission(kgCO2emission(kg--co2eq/1peiceco2eq/1peice・・1season)1season)

LCALCA



Energy saving-the impact of 80 mil pieces

The effect of CO2 reduction derived from 80 million pieces The effect of CO2 reduction derived from 80 million pieces

13kg13kg--co2/garmentco2/garment・・season x season x 80,000,00080,000,000 HEATTECH = HEATTECH = 1,040,000 1,040,000 tonton--co2 co2

equating to cedar tree equating to cedar tree 74,290,00074,290,000 pieces = forest area of pieces = forest area of 831k831k㎡㎡

40% size of New Taipei City40% size of New Taipei City

The amount of CO2 emissions reduced by HEATTECH garment is nearly equivalent to the amount of CO2 absorbed by a 50-year-old

cedar tree

Equates

to



Energy saving-the effect of energy saving

58w58w/ family unit x / family unit x 10,000,00010,000,000 family unit = family unit = 580,000580,000 kwkw

1.0℃ reduction in thermostat settings

The amount of reduction of power consumption isThe amount of reduction of power consumption is58w58w per family unitper family unit

We Japanese face electric power shortage because of nuclear poweWe Japanese face electric power shortage because of nuclear power outage. r outage. (operation rate is 40% lower)(operation rate is 40% lower)

The GOJ declared that the power shortage this winter will be The GOJ declared that the power shortage this winter will be 1,130,000kw1,130,000kw

If 10 mil family unit cut off 1If 10 mil family unit cut off 1℃℃ in thermostat setting due to wearing HEATTECH,in thermostat setting due to wearing HEATTECH,

half of power shortage is improved. half of power shortage is improved.

This is the big appeal point!This is the big appeal point!



Energy saving- article regarding HEATTECH

日経新聞日経新聞8/268/26 読売新聞読売新聞8/268/26 毎日新聞毎日新聞8/268/26

産経新聞産経新聞8/268/26

definition definition regarding energy regarding energy savingsaving

At a press conference on August 25, At a press conference on August 25, UniqloUniqlo and Toray and Toray announced their HEATTECH sales target for 2011 and the announced their HEATTECH sales target for 2011 and the potential for efficient energy saving of this product.potential for efficient energy saving of this product.

The next day, major newspapers wrote about it. The next day, major newspapers wrote about it.



Life Cycle of FeedstockDepletion of Fossil Resources

Fossil Resources Power

Feedstock

Heat

2010 2050 ・・・

Biomass Feedstock


IncinerationDisposal

Biomass FeedstockBiomass Feedstock

Polymer Polymer

Bio-based Polymer Products（Plastics・Films・Fibers）

Bio-based Polymer Products（Plastics・Films・Fibers）

ＣＯ２

Water

Photo synthesis

Incineration/Decomposition

Fermentation

Renewable Monomer Monomer

PolymerPolymer

Fossil MaterialFossil Material

Fossil-basedPolymer Products

Fossil-basedPolymer Products

Polymerization

MonomerMonomer

PetroleumRefinery& Synthesis

Recycle

C. J. Campbell, et al.ASPO (2004)

（year）

Biomass-Innovative materials for fibers

Appeal point : Conserving limited fossil resourcesAppeal point : Conserving limited fossil resources

Target : Companies Target : Companies



Biomass-TORAY’s commercialization bio-based polymer

1,3-propanediol

Lactic acid

Sebacic acid

Modified cellulose

3GT “sorona”

PLA”Ingeo”

Nylon610

ThermoplasticCellulose

Polymer Fibers＆textiles Brand name

Fitty

Ecodear

Amilan

Foresse

1.Toray’s Bio-based Polymer

Biomass

Biomass conversion technology Improving property technology to use biopolymer

3GT3GT

PLAPLA

HeatHeat--shrinkageshrinkage

DurabilityDurability

HydrolysisHydrolysis

Low HeatLow Heat--resistantresistant

DurabilityDurability

3GT

petroleum based

material

PLA

petroleum based

material

2.Toray’s technology <Property problem><Property problem> <complex technology><complex technology>

by DuPont

by NatureWorks



Biomass- applications

Luggage trim :PLA

Headlining:3GT

Door trim base material :PLA

Sun visor:3GT

Pillar:3GT

Floor mat :PLA

<automotive><automotive> <anti<anti--desertification>desertification>

PLA TubesPLA Tubes

<household goods/others><household goods/others>disposal disposal net PLAnet PLA

Net forNet forpreventingpreventing

animal damageanimal damagefiber fillfiber fill

PLAPLAtea bagtea bag

PLAPLA

ApparelApparel3GT3GT



Biomass- LCA

PLAPLA

““IngeoIngeo””

3GT3GT

““soronasorona””



Recycle-Toray’s recycling system

ReproductionReproduction Collection and Circulation

Collection and Circulation

–Less Energy Recycling–TORAY’s Total Recycling for Fibers & Textiles

Appeal point : Appeal point : conserving limited fossil resourceconserving limited fossil resource

Target : company Target : company



Recycle-Collection and Circulation Recycling : : Toray’s Joint Work with Patagonia

TORAYTORAY

Consumers

Nylon6Fabrics

Nylon6Fibers

Pre-treatmentRemoval of Non-Nylon6

Substance (zipper, button, etc.)

Chemical Recycle(Depolymerization)

PolymerizationSynthesis

Spinning, Weaving

Sales

Raw materialCyclohexane

Nylon6Process Waste

Collection

PatagoniaPatagonia

Sales

Sales

2000 stores in 12 countries

CaprolactamCrude

Caprolactam

Online Purification



Recycle-

Collected Plastic Bottles

Reproduction Recycling : material recycling (PET Recycling Type)

Apparel Makers, etc.

FabricsNon-woven Fabrics, Fiberfill

Filament yarn& Staple fiber

TORAYTORAY

Consumers Private firms, governmental offices

PelletsScrapfilm, fiber, Fabrics

TORAYTORAY



‥‥‥

‥‥‥

‥‥‥

‥‥‥

【 chemical recycle : PET100% Uniform 】material manufa

cturinguse disposal LCA

virgin １５.７７.７０７.６３１.０

recycle １３.０９.５０６.１２８.６

material manufacturing

use disposal LCA

virgin １０.４５.１０５.１２０.６

recycle ８.６５.２０４.３１８.１

ＣＯ２ reduction

２.４（kg-CO2／kg）

２.５（kg-CO2／kg）

【 material recycle : PET100% Nonwoven 】

The amount of

Toray’s recycling fiber

18,000ton/year

Recycle- LCA

Impact on CO2 emissions during the product lifecycle

ＣＯ２ reduction

Cedar tree3.1million

＝××2.4

kg-CO2/kg

equates toequates to

43,000(ton-CO2/year)

*calculating through basket method*calculating through basket method



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Ⅳ．Conclusion

Ⅴ．Message


Ⅳ.Conclusion

ⅠⅠ．．All Toray group company members share the global issues and addrAll Toray group company members share the global issues and address ess toto expand the Green Innovation business.expand the Green Innovation business.

ⅡⅡ．．Viewed from an LCA perspective, generally the amount of CO2 emisViewed from an LCA perspective, generally the amount of CO2 emission sion during usage is more than that during manufacturing. Therduring usage is more than that during manufacturing. Therefore it is efore it is important to reduce CO2 emissions not only during manufactimportant to reduce CO2 emissions not only during manufacturing but uring but also during usage. also during usage.

ⅢⅢ．．HEATTECHHEATTECH’’ss match of efficiency and price caused a big hit in Japan match of efficiency and price caused a big hit in Japan and the Japanese accept its effect of energy saving under and the Japanese accept its effect of energy saving under recent power recent power shortage conditions. To visualize the environmental effectshortage conditions. To visualize the environmental effect by LCA isby LCA isthe efficient way for consumersthe efficient way for consumers. .

ⅣⅣ．．Biomass and recycling productsBiomass and recycling products are not expanding because of more are not expanding because of more expensive cost than conventional one. Despite these premiuexpensive cost than conventional one. Despite these premium costs, the m costs, the environmentally conscious image that these products portraenvironmentally conscious image that these products portray can be y can be used as a form marketing to offset the costs and help ecolused as a form marketing to offset the costs and help ecology. As ogy. As technologies advance and new methods are developed in thistechnologies advance and new methods are developed in this area, area, costs will be reduced and these products will take off.costs will be reduced and these products will take off.


Ⅴ.Message

We would like to express our gratitude and say We would like to express our gratitude and say ““Thank YouThank You””for the aid and support we received from all countries in the for the aid and support we received from all countries in the wake of Japanwake of Japan’’s triple disaster this past Spring.s triple disaster this past Spring.

The huge disaster on March 11The huge disaster on March 11thth changed Japanchanged Japan’’s way of life. s way of life. We are more conscious of energy saving than before, and We are more conscious of energy saving than before, and therefore ecotherefore eco--conscious productsconscious products are acceptable for us now.are acceptable for us now.

The catastrophe taught us that we can change our lifestyle for The catastrophe taught us that we can change our lifestyle for the better.the better.

Internationally, we will all have to change our way of life Internationally, we will all have to change our way of life towards more sustainable and ecotowards more sustainable and eco--friendly activities in the friendly activities in the future. future.


Thank you for your attention.

Documents

Symbol of TORAY’s environmental action Toray s Action for ...news.textiles.org.tw/2011sustainabilityforum/PPT/Session II/TITAS... · Toray’s Action for the Global Environment