In addressing the pressing challenges of global climate change and resource scarcity, textile recycling is poised to become a crucial direction for future industrial development. Herein, the raw material sources, production processes, and product attributes of recycled polyester are comprehensively considered based on the product life cycle assessment (LCA) methodologies and the allocation principles outlined in international standards ISO 14040/14044. It establishes carbon emission allocation factors and computational models tailored to real-world production contexts. The global warming potential (GWP), primary energy demand (PED), and water usage (WU) of polyester staple fibers (PSFs) and recycled polyester staple fibers (RPSFs) (produced via bottle flake spinning and popcorn spinning) in mainland China in 2021 were compared. The findings of this study reveal that RPSF possesses notable advantages in mitigating carbon emissions, conserving energy, and reducing water usage. Notably, RPSF produced through the popcorn spinning process demonstrated superior performance, with GWP, PED, and WU being 48%, 46%, and 33% lower, respectively, compared to PSF. The analysis of the LCA of RPSF and the production practices of representative enterprises in China indicates that recycled chemical fibers contribute to fostering green and low-carbon development within the chemical fiber industry.
