Process innovations drive efficiency and sustainability

Process innovations focus on improvements to pulp and fiber production processes. Ongoing developments in pulp production aim to enhance the biorefinery concept, thereby optimizing wood consumption. Another issue is the reduction of sulfur emissions through technological improvements and aftertreatment systems. These measures allow effective cleaning of the exhaust gases as well as compliance with (or levels that surpass) the emission regulations.

The foundation for sustainable innovations is the use of highly sophisticated production processes for pulp (including biorefinery products) and fibers (viscose, modal and lyocell). The lyocell technology platform has already been expanded to include the production of additional materials, namely filament and direct-spun web. A number of new innovations have been developed in recent years that have not only significantly improved the lyocell process in terms of efficiency and quality but also reduced energy, water and process chemical consumption, thereby further improving the lyocell process.

Although Lenzing’s headquarters are in Central Europe, the group operates multiple production sites all over the world. Driven by European legislation on the one hand and market demand for higher standards related to environmental impact and product sustainability on the other, Lenzing continued its efforts to meet European standards in 2024, at both its European production sites and global locations.

Apart from product development, Lenzing also focuses on operational improvements to remove water from different process streams more efficiently compared to standard evaporation technologies, which are very energy-intensive. Such technology upgrades contribute to a further reduction in energy consumption and therefore the carbon footprint as well as other impacts related to fiber production. In addition, other projects are ongoing to improve chemical consumption.

These activities are accompanied and supported by simulation and modeling. In the near future, Lenzing is planning to significantly enhance its textile recycling activities, which is a very challenging task that includes the production of recycling pulp as well as the handling of recycling pulp processability in different fiber production processes. Success requires a holistic approach ranging from pulp to fiber production and to final applications in textiles and nonwovens.

One current focus is boosting biorefinery integration at Lenzing’s pulp sites and therefore increasing the use of the raw material wood. Several projects related to pulp production deal with the closure of loops (e.g. selective sulfur dioxide adsorption, increased caustic soda recovery) and the reduction of wastewater (e.g. sulfate in pulp and viscose fiber production). Increasing energy efficiency and reducing carbon emissions are other topics of growing importance.