Spun-bonded non-woven fabric production carbon footprint modular accounting method

Abstract

The invention provides a spunbonded non-woven fabric production carbon footprint modular accounting method, which comprises the following steps that: a spunbonded non-woven fabric production carbon footprint accounting model is constructed, and the spunbonded non-woven fabric production carbon footprint accounting model comprises a net forming module, a reinforcing module and a slitting and packaging module; acquiring life cycle data of the spun-bonded non-woven fabric production process, wherein the life cycle data comprises energy consumption and resource consumption of the spun-bonded non-woven fabric production process; the life cycle data is substituted into the spunbonded non-woven fabric production carbon footprint accounting model to calculate the carbon footprint in the spunbonded non-woven fabric production process, the spunbonded non-woven fabric production carbon footprint is quantified from three modules of web forming, reinforcing and slitting packaging, and the blank of the spunbonded non-woven fabric production carbon footprint modular accounting method is filled.

Description

Technical Field

[0001] The present invention relates to the field of greenhouse gas management in the spunbond nonwoven fabric industry, and in particular to a modular carbon footprint accounting method for spunbond nonwoven fabric production based on a carbon footprint accounting method and modularization theory. Background Art

[0002] Spunbond nonwoven fabrics are the main raw materials for industrial textiles and are widely used in many fields. For example, in the medical and health field, they are often used to make disposable surgical gowns, masks, sanitary care products, etc. Their good barrier properties and breathability can effectively prevent the spread of bacteria and viruses and protect the health of medical staff and patients.

[0003] The production process of spunbond nonwoven fabrics is relatively complex and delicate. The polymer slices need to be sliced first, and then the polymer slices are transported to the heating equipment. After gradually heating up to about 160-230°C, they are completely extruded and melted into a uniform melt. When the melt reaches the ideal state, it will be ejected from the spinneret in the form of extremely fine filaments. These filaments are rapidly stretched and thinned under the stretching action of the high-speed airflow, and are randomly distributed in space, gradually forming a uniform fiber web. Subsequently, they need to be consolidated into cloth through different reinforcement methods (such as hot rolling, needle punching, hydroentanglement, chemical bonding, etc.), and the non-woven fabric products are obtained after winding, slitting and packaging.

[0004] Despite the widespread and important applications of spunbond nonwovens in various fields, their production process presents significant environmental challenges. In terms of energy consumption, in addition to the significant amount of electricity required to operate the production equipment itself, the water and chemical adhesives consumed during the hydroentanglement and chemical bonding processes not only increase production costs but also place additional strain on the environment. During the hydroentanglement process, approximately 10-20 cubic meters of water are consumed for every ton of spunbond nonwovens produced. This water often contains significant amounts of fiber debris and chemicals. If discharged without effective treatment, it can pollute the aquatic ecosystem. Some of the chemical adhesives used in chemical bonding may contain volatile organic compounds (VOCs), which evaporate into the air during production and use, polluting the atmosphere. Furthermore, the subsequent drying process, whether using hot air drying or other drying methods, consumes significant amounts of electricity, further exacerbating energy consumption and greenhouse gas emissions.

[0005] However, the production of large quantities of spunbond nonwovens consumes a lot of electricity, which indirectly causes greenhouse gas emissions. In addition to the electricity consumption of the production equipment itself, hydroentanglement and chemical bonding reinforcement also consume water resources and chemical adhesives, and subsequent electricity drying is consumed. Promoting energy conservation and carbon reduction has become a key content for the development of the spunbond nonwovens industry. Summary of the Invention

[0006] The purpose of the present invention is to provide a modular accounting method for the carbon footprint of spunbond nonwoven fabric production, which quantifies the carbon footprint of spunbond nonwoven fabric production from three modules: web forming, reinforcement, and slitting and packaging, thus filling the gap in the modular accounting method for the carbon footprint of spunbond nonwoven fabric production.

[0007] To achieve the above objectives, the present technical solution provides a modular accounting method for the carbon footprint of spunbond nonwoven fabric production, comprising the following steps: (1) Constructing a carbon footprint accounting model for spunbond nonwovens production, which includes a web forming module, a reinforcement module, and a slitting and packaging module; (2) Obtain life cycle data of the spunbond nonwovens production process, where the life cycle data includes energy consumption and resource consumption of the spunbond nonwovens production process; (3) Substitute the life cycle data into the carbon footprint accounting model for spunbond nonwoven production to calculate the carbon footprint of the spunbond nonwoven production process. The carbon footprint calculation formula of the spunbond nonwoven production carbon footprint accounting model is as follows: ; in CF 纺粘 Carbon footprint for spunbond nonwoven production, CF 加固,i is the carbon footprint of the i-th reinforcement method, i is the reinforcement type, n is the total number of reinforcement types, CF 成网 is the carbon footprint of the web module, CF 分切包装 Carbon footprint of the slitting and packaging modules.

[0008] In step (1), a web-forming module of a carbon footprint accounting model for spunbond nonwoven fabric production is constructed based on the raw material composition, wherein the web-forming module for polypropylene raw materials consists of a corresponding polymer feeding process unit, a metering and mixing process unit, a melt extrusion process unit, a melt filtration process unit, a fiber forming process unit, a fiber cooling process unit, a drawing process unit and a web-forming process unit; and the web-forming module for polyester and polylactic acid raw materials consists of a corresponding drying and feeding process unit, a polymer feeding process unit, a metering and mixing process unit, a melt extrusion process unit, a melt filtration process unit, a fiber forming process unit, a fiber cooling process unit, a drawing process unit and a web-forming process unit.

[0009] In step (1), a reinforcement module of the carbon footprint accounting model for spunbond nonwoven fabric production is constructed based on the reinforcement process, wherein the reinforcement process is one of mechanical reinforcement, chemical bonding reinforcement and thermal bonding reinforcement. When the reinforcement process is mechanical reinforcement, the mechanical reinforcement is selected from one of needle punching, hydroentanglement and stitching; when the reinforcement process is chemical bonding reinforcement, the chemical bonding reinforcement is selected from one of impregnation, spraying, foaming, printing and solvent bonding; when the reinforcement process is thermal bonding reinforcement, the thermal bonding reinforcement is selected from one of hot melt, hot rolling and ultrasonic bonding.

[0010] Furthermore, full-width, continuous spunbond nonwovens require slitting, winding, and packaging to produce products of the required specifications (roll length and width) for the market. Therefore, the spunbond nonwoven production carbon footprint calculation model also includes a slitting and packaging module. This module consists of the slitting, winding, and packaging process units.

[0011] In step (2), the energy in the life cycle data covers various energy types such as electricity, coal, and natural gas; resources include water resources, raw materials, packaging materials, and other resources. Accurately obtaining this data is the basis for carbon footprint accounting.

[0012] In step (3), the life cycle data is substituted into the carbon footprint accounting model for spunbond nonwoven fabric production to calculate the carbon footprints of the web-forming module, the reinforcement module, and the slitting and packaging module. The carbon footprints of the web-forming module, the reinforcement module, and the slitting and packaging module are summarized to obtain the carbon footprint of the spunbond nonwoven fabric production carbon footprint accounting model.

[0013] The carbon footprint calculation formula for the web-forming module is as follows: ; in CF 成网 is the carbon footprint of the web-forming module, in kg CO2eq, E i is the energy consumption of the i-th energy in the web-forming process step of the corresponding web-forming module, EF i is the carbon emission factor of the i-th energy source, M j is the resource consumption of the jth resource, EF j is the carbon emission factor of the jth resource, n is the energy type, and m is the resource type.

[0014] Specifically, E i is the energy consumption of the i-th energy source in each process unit including drying, polymer feeding, metering and mixing, melt extrusion, melt filtration, fiber formation, fiber cooling, drawing and web forming.

[0015] When the reinforcement process is mechanical reinforcement needle punching, the carbon footprint of the reinforcement module is calculated as follows: ; in CF 加固,针刺 is the carbon footprint of the reinforcement module when the reinforcement process is mechanical reinforcement needle punching, E 能源 is the energy consumption of the acupuncture equipment, EF 能源 is the carbon emission factor of energy.

[0016] When the reinforcement process is mechanical reinforcement by hydroentanglement, the carbon footprint of the reinforcement module is calculated as follows: ; in CF 加固,水刺 is the carbon footprint of the reinforcement module when the reinforcement process is mechanical reinforcement and hydroentanglement, in kg CO2eq, E i is the energy consumption of the i-th energy source of the spunlace equipment, EF i is the carbon emission factor of the i-th energy source, n is the type of energy, M 水 The water resource consumption of the spunlace equipment is EF 水 is the carbon emission factor of water resources.

[0017] When the reinforcement process is mechanical reinforcement stitching, the carbon footprint of the reinforcement module is calculated as follows: ; in CF 加固,缝编 is the carbon footprint of the reinforcement module when the reinforcement process is mechanical reinforcement stitching, in kg CO2eq, E 能源 is the energy consumption of the acupuncture equipment, EF 能源 is the carbon emission factor of energy, M i is the resource consumption of stitching yarn i in the i-th stitching, EF i is the carbon emission factor of stitching yarn i, and n is the type of stitching yarn.

[0018] When the reinforcement process is chemical bonding, the carbon footprint of the reinforcement module is calculated as follows: ; in CF 加固,化学黏合is the carbon footprint of the reinforcement module when the reinforcement process is chemical bonding, in kg CO2eq, E i is the energy consumption of the i-th energy source of the chemical bonding equipment, EF i is the carbon emission factor of the i-th energy source, M j is the resource consumption of the jth adhesive, EF j is the carbon emission factor of the jth adhesive, n is the energy type, and m is the adhesive type.

[0019] It should be noted that, as mentioned above, the above carbon footprint calculation formula is applicable when the chemical bonding method is dipping method, spraying method, foam method, printing method, or solvent bonding method.

[0020] When the reinforcement process is thermal bonding, the carbon footprint of the reinforcement module is calculated as follows: ; in CF 加固,热黏合 is the carbon footprint of the reinforcement module when the reinforcement process is thermal bonding, in kg CO2eq, E 能源 is the energy consumption of thermal bonding equipment, EF 能源 is the carbon emission factor of energy.

[0021] It should be noted that, as mentioned above, the above carbon footprint calculation formula is applicable when the thermal bonding is performed by hot melt method, hot rolling method, or ultrasonic bonding method.

[0022] The calculation formula for the carbon footprint of the cutting and packaging module is as follows: ; in CF 分切包装 The carbon footprint of the packaging module is expressed in kg CO2eq. CF 分切 is the carbon footprint of the slitting process unit, CF 卷绕 is the carbon footprint of the winding process unit, CF 包装 is the carbon footprint of the packaging process unit, E 能源 is the energy consumption of the slitting and winding packaging equipment, EF 能源 is the carbon emission factor of energy, M i is the total consumption of the i-th packaging material, EF iis the carbon emission factor of the i-th packaging material, and n is the type of packaging material.

[0023] In addition, in some embodiments, the calling and combination configuration of the web forming module, the reinforcement module, and the slitting and packaging module can be used to evaluate and compare the carbon footprint of spunbond nonwoven fabric production with different production processes; the carbon footprint of similar spunbond nonwoven fabric product production can also be estimated by calling and combination configuration of basic, partially modified, and modular carbon footprint units with similar functions.

[0024] Compared with the existing technology, this technical solution has the following characteristics and beneficial effects: This study uses life cycle theory, carbon footprint accounting method and modular method to quantify the carbon footprint of spunbond nonwoven fabric production. By analyzing the three key modules of web forming, reinforcement, and slitting and packaging, it achieves accurate quantification of the carbon footprint of spunbond nonwoven fabric production, providing a scientific basis for carbon emission management in the textile industry. It aims to utilize the universality of the carbon footprint unit module data of spunbond nonwoven fabric production to reduce the repetitive labor of repeated data collection, thereby calculating and estimating the carbon footprint of spunbond nonwoven fabric production with similar production processes. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 Diagram of the architecture of the carbon footprint accounting model for spunbond nonwovens production. DETAILED DESCRIPTION

[0026] The present invention uses life cycle theory, carbon footprint calculation method and modular method to quantify the carbon footprint of spunbond nonwoven fabric production. It aims to use the universal characteristics of the carbon footprint unit module data of spunbond nonwoven fabric production to reduce the repetitive labor of repeated data collection, thereby calculating and estimating the carbon footprint of spunbond nonwoven fabric production with similar production processes.

[0027] Specific application examples are as follows: Taking the production of a 25g*19cm spunbond nonwoven fabric (declaration unit: production of 1 ton of spunbond nonwoven fabric) as an example, the raw material is polypropylene. The calculation of the carbon footprint accounting model for spunbond nonwoven production includes the following steps: Step (1): According to the production process of the product, a carbon footprint accounting model for the production of spunbond nonwoven fabrics is constructed, including a web forming module, a reinforcement module, and a slitting and packaging module. The web forming module processes include a polymer feeding process unit, a metering and mixing process unit, a melt extrusion process unit, a melt filtration process unit, a fiber forming process unit, a fiber cooling process unit, a drawing process unit, and a web forming process unit. The reinforcement module is a hot rolling method in thermal bonding reinforcement. The slitting and packaging module includes a slitting process unit, a winding process unit, and a packaging process unit.

[0028] Step (2): The carbon emission source of the web-forming module and the reinforcement module is electricity. Electricity is widely used in various processes of these modules to drive the operation of various equipment, such as screw extruders, metering pumps, airflow web-forming equipment, web-forming conveying equipment and rolling mills. The carbon emission sources of the slitting and packaging module are electricity, winding shafts (paper) and polyethylene packaging bags. The production, transportation and use of winding shafts and packaging bags will generate certain carbon emissions. The accounting list is shown in Table 1. The carbon footprints of the web-forming module, reinforcement module and slitting and packaging module are calculated according to the corresponding carbon footprint calculation formula.

[0029] Table 1 Calculation list for producing 1 ton of spunbond nonwoven fabric with specifications of 25g*19cm

[0030] Step (3): Summarize the carbon footprint values of the production of spunbond nonwoven fabric products. The production carbon footprint calculation results are shown in Table 2: Table 2 Carbon footprint of producing 1 ton of spunbond nonwoven fabric with specifications of 25g*19cm

[0031] The carbon footprint calculation results for production show that the web-forming module has a carbon footprint of 196.38 kg CO₂eq, the reinforcement module has a carbon footprint of 50.99 kg CO₂eq, and the slitting and packaging module has a carbon footprint of 54.40 kg CO₂eq. These data indicate that the web-forming module has a significant carbon footprint, primarily due to the complex processes involved in web-forming and the high electricity consumption required. While the carbon footprints of the reinforcement and slitting and packaging modules are relatively small, they are still significant. By analyzing the carbon footprint of each module, targeted emission reduction measures can be developed, such as optimizing the energy efficiency of web-forming equipment, improving reinforcement processes, and selecting more environmentally friendly packaging materials.

[0032] The above are only specific embodiments of the present invention, but the technical features of the present invention are not limited thereto. Any simple changes, equivalent substitutions, or modifications based on the present invention to solve substantially the same technical problems and achieve substantially the same technical effects are included within the scope of protection of the present invention.

Claims

1. A modular accounting method for carbon footprint of spunbond nonwoven production, characterized in that: The following steps are involved: (1) Constructing a carbon footprint accounting model for spunbond nonwovens production, which includes a web forming module, a reinforcement module, and a slitting and packaging module; (2) Obtain life cycle data of the spunbond nonwovens production process, where the life cycle data includes energy consumption and resource consumption of the spunbond nonwovens production process; (3) Substitute the life cycle data into the carbon footprint accounting model for spunbond nonwoven production to calculate the carbon footprint of the spunbond nonwoven production process. The carbon footprint calculation formula of the spunbond nonwoven production carbon footprint accounting model is as follows: ； in CF 纺粘 Carbon footprint for spunbond nonwoven production, CF 加固,i is the carbon footprint of the i-th reinforcement method, i is the reinforcement type, n is the total number of reinforcement types, CF 成网 is the carbon footprint of the web module, CF 分切包装 Carbon footprint of the slitting and packaging modules.

2. The modular carbon footprint calculation method for spunbond nonwoven production according to claim 1, characterized in that: The web-forming module of the carbon footprint accounting model for spunbond nonwoven fabric production is constructed according to the raw material composition. The web-forming module for polypropylene raw materials consists of the corresponding polymer feeding process unit, metering and mixing process unit, melt extrusion process unit, melt filtration process unit, fiber formation process unit, fiber cooling process unit, drawing process unit and web-forming process unit; the web-forming module for polyester and polylactic acid raw materials consists of the corresponding drying feeding process unit, polymer feeding process unit, metering and mixing process unit, melt extrusion process unit, melt filtration process unit, fiber formation process unit, fiber cooling process unit, drawing process unit and web-forming process unit.

3. The modularized carbon footprint calculation method for spunbond nonwoven production according to claim 1, characterized in that: A reinforcement module of a carbon footprint accounting model for spunbond nonwoven fabric production is constructed according to the reinforcement process, wherein the reinforcement process is one of mechanical reinforcement, chemical bonding reinforcement and thermal bonding reinforcement. When the reinforcement process is mechanical reinforcement, the mechanical reinforcement is selected from one of a needle punching method, a hydroentanglement method and a stitching method; when the reinforcement process is chemical bonding reinforcement, the chemical bonding reinforcement is selected from one of an impregnation method, a spraying method, a foam method, a printing method and a solvent bonding method; when the reinforcement process is thermal bonding reinforcement, the thermal bonding reinforcement is selected from one of a hot melt method, a hot rolling method and an ultrasonic bonding method.

4. The modular carbon footprint calculation method for spunbond nonwoven production according to claim 1, characterized in that: The slitting and packaging module consists of a corresponding slitting process unit, a winding process unit and a packaging process unit.

5. The modularized carbon footprint calculation method for spunbond nonwoven production according to claim 1, characterized in that: The life cycle data is substituted into the carbon footprint accounting model of spunbond nonwoven fabric production to calculate the carbon footprint of the web-forming module, reinforcement module and slitting and packaging module. The carbon footprints of the web-forming module, reinforcement module and slitting and packaging module are summarized to obtain the carbon footprint of the spunbond nonwoven fabric production carbon footprint accounting model.

6. The modularized carbon footprint calculation method for spunbond nonwoven production according to claim 5, characterized in that: The carbon footprint of the web-forming module is calculated as follows: ； in CF 成网 is the carbon footprint of the web module, in kg CO2eq, E i is the energy consumption of the i-th energy in the web-forming process step of the corresponding web-forming module, EF i is the carbon emission factor of the i-th energy source, M j is the resource consumption of the jth resource, EF j is the carbon emission factor of the jth resource, n is the energy type, and m is the resource type.

7. The modularized carbon footprint calculation method for spunbond nonwoven production according to claim 5, characterized in that: When the reinforcement process is mechanical reinforcement needle punching, the carbon footprint of the reinforcement module is calculated as follows: ； in CF 加固,针刺 is the carbon footprint of the reinforcement module when the reinforcement process is mechanical reinforcement needle punching, in kgCO2eq, E 能源 is the energy consumption of the acupuncture equipment, EF 能源 is the carbon emission factor of energy; When the reinforcement process is mechanical reinforcement by hydroentanglement, the carbon footprint of the reinforcement module is calculated as follows: ； in CF 加固,水刺 is the carbon footprint of the reinforcement module when the reinforcement process is mechanical reinforcement hydroentanglement, in kgCO2eq, E i is the energy consumption of the i-th energy source of the spunlace equipment, EF i is the carbon emission factor of the i-th energy source, n is the type of energy, M 水 The water resource consumption of the spunlace equipment is EF 水 is the carbon emission factor of water resources; When the reinforcement process is mechanical reinforcement stitching, the carbon footprint of the reinforcement module is calculated as follows: ； in CF 加固,缝编 is the carbon footprint of the reinforcement module when the reinforcement process is mechanical reinforcement stitching, in kgCO2eq, E 能源 is the energy consumption of the acupuncture equipment, EF 能源 is the carbon emission factor of energy, M i is the resource consumption of stitching yarn i in the i-th stitching, EF i is the carbon emission factor of stitching yarn i, and n is the type of stitching yarn.

8. The modularized carbon footprint calculation method for spunbond nonwoven production according to claim 5, characterized in that: When the reinforcement process is chemical bonding, the carbon footprint of the reinforcement module is calculated as follows: ； in CF 加固,化学黏合 is the carbon footprint of the reinforcement module when the reinforcement process is chemical bonding, in kg CO2eq, E i is the energy consumption of the i-th energy source of the chemical bonding equipment, EF i is the carbon emission factor of the i-th energy source, M j is the resource consumption of the jth adhesive, EF j is the carbon emission factor of the jth adhesive, n is the energy type, and m is the adhesive type.

9. The modularized carbon footprint calculation method for spunbond nonwoven production according to claim 5, characterized in that: When the reinforcement process is thermal bonding, the carbon footprint of the reinforcement module is calculated as follows: ； in CF 加固,热黏合 is the carbon footprint of the reinforcement module when the reinforcement process is thermal bonding, in kg CO2eq, E 能源 is the energy consumption of thermal bonding equipment, EF 能源 is the carbon emission factor of energy.

10. The modularized carbon footprint calculation method for spunbond nonwoven production according to claim 1, characterized in that: The carbon footprint of the cutting and packaging module is calculated as follows: ； in CF 分切包装 The carbon footprint of the packaging module is expressed in kg CO2eq. CF 分切 is the carbon footprint of the slitting process unit, CF 卷绕 is the carbon footprint of the winding process unit, CF 包装 is the carbon footprint of the packaging process unit, E 能源 is the energy consumption of the slitting and winding packaging equipment, EF 能源 is the carbon emission factor of energy, M i is the total consumption of the i-th packaging material, EF i is the carbon emission factor of the i-th packaging material, and n is the type of packaging material.

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