Opportunities, Through Green Chemistry, for Improving ... · [2] Akuvali, Guneri (2008)....

TE/TT Senior Design 2013-2014

Introduction & Motivation Types of Processing

Sponsorship & Acknowledgements

Faculty Mentors: Dr. Jon Rust, Dr. Russell Gorga, & Dr. Jesse Jur

This project is sponsored by NIKE, inc.

Opportunities, Through Green Chemistry, for Improving Synthetic Leather Joseph DiCesare, Edgardo Lopez, Jackie Revels Spring 2014

Company Mentor: Samantha Shintay

Customer Needs

Conclusion & Next Steps

15 million kg of synthetic leather is used per year at Nike One line of production equals $18,625 in sewage treatment

costs (approximately 170 lines in Wenzhou China total of about $3,000,000) [1]

Nike is seeking to eliminate discharge of hazardous chemicals during the manufacturing of their products by 2020

Nike is constantly seeking to reduce…

Assess the current state of synthetic leather production Survey and catalog sustainable methods for improving

synthetic leather process and materials Rank and assess the quality, economic, and environmental

impact of each method in order to provide recommendations to Nike

Rank and quantify improvements based on Nike's Restricted Substances List (RSL) criteria and The 12 Principles of Green Chemistry

RSL is given to suppliers to promote the use of positive chemistry and processes

Use a selection of the 12 Principles of Green Chemistry

Rank individual processes rather than companies, based on sustainability

Customers should expect an increased cost for solvent free materials Vendors are making an effort towards more sustainable synthetic

leather manufacturing. Explore options to replace DMF and other harmful solvents with

environmentally friendly compounds.

Water Borne Polyurethane can be used in processes to eliminate or significantly reduce the use of harmful solvents (Table 1) (Figure 2).

TPU (thermoplastic polyurethane) is another option that allows for the elimination of harmful solvents. Only used with high density substrates, typically with some form of nonwoven [2].

Recycled polyester for use as a backer is a viable option. Little to no compromise of mechanical properties [3].

The reduction or elimination of harmful solvents highly reduces water and energy consumption.

Overall, vendors are working towards Nike’s goal of no harmful chemical discharge by 2020

Figure 1: Green Chemistry

[1] Xu Xu (2011). "Environmental Cost Analysis and Upgrading Research of Synthetic Leather Industry".Energy procedia, 5.

[2] Akuvali, Guneri (2008). "Advances in Polymer Coated Textiles“. [3] Documents obtained from Teijin. [4] Image from documents obtained from Clarino

1, 2, 3

Research Current Manufacturing

Processes

Landscape Methods &

Advancements

Rank & Quantify Improvements Based on Nike's Green Chemistry

Program

Project Process

Toxics Energy Consumption Waste

Water Consumption

Project Description

Project Criteria

ACS Chemistry for Life: http://www.acs.org/content/acs/en.html

Pocket Guide

Recommendation 1. Elimination of harmful solvents: (1) Prevention, (3)Less hazardous

chemical synthesis, (5) Safer solvents and auxiliaries 2. Reduced energy & water consumption: (1) Prevention 3. Recycled substrates & water: (1) Prevention, (7) Use of renewable

feed stocks 4. Non-woven composite could potentially improve mechanical

properties.

Results 2

Results 1

Selected Survey Responses How do you see the future of sustainable synthetic leather?

How does your company currently practice sustainable practices?

“The customer only cares about quality and price, not how it was made” “Using water based polyurethane” “No solvent usage, or toxic gas emission”

“We developed a way to make synthetic leather without using a solvent.” “We use a water based polyurethane resin” “Our company uses eco-friendly materials, such as recycled polyester”

Are there any emerging technologies that could improve the process?

“Expanding the use of recycled substrate material.” “Waste water recycling systems.”

Figure 2: Layers of a Water Based PU Synthetic Leather

Results 3

-Wet + Dry combination of the R/P dry process being laminated to the wet process backers

-Dry includes producing the finish on release papers and laminating to non wet process backers

-Wet impregnation and coating of the backer to give material body and cushioning and better roller emboss definition

Ideation Process -Eight question survey focusing on the companies solvents, methods, and processing with an emphasis on green chemistry and sustainability -Distributed to representatives of 6 individual companies -Responses helped formulate recommendation to addressed customer needs

• Wenzhou China would save $1,108,187.50 in water treatment if half their lines go solvent free.

Figure 3: Process Steps for Water Borne PU Synthetic Leather

Table 1