Advances in Flame Retardant Chemicals

Krzysztof Grzybowski, Industry Analyst

CMF – Technical Insights

August 21, 2008

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Agenda

•Types of Flame Retardants (FR)

•FR Challenges

•FR Technology Accelerators

•Phasing Out Halogenated FR

•FR R&D

•FR Technology Examples

3

History of Flame Retardants

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Fire Intensity and Economic Impact

Fires

1,400,000

1,450,000

1,500,000

1,550,000

1,600,000

1,650,000

1,700,000

1,750,000

1,800,000

1,850,000

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

Year

Num

ber

of Fir

es in U

S

Fire accidents aremore frequent

5

Fire Intensity and Economic Impact (cont.)

Dollar loss in millions

8,525

8,629

10,024

11,207

10,583

10,337

12,307

9,794

10,672

11,307

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

Dollar loss in millions

Fires have a

significant impact on economies

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• How can you assure flame retardant material without affecting functionality?

• Would clients accept products with built-in flame retardant additives?

• How can you improve non-flammability without a price increase?

• Are flame retardant regulations going to become more stringent?

Essential Flame Retardant Questions

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Types of FR

phosphorus-

based flame

retardants

nitrogen-containing

flame retardants,

which includes

melamine and its

derivatives

halogenated

flame retardants

like brominated

and chlorinated

flame retardants

metal hydroxides

such as aluminum

trihydroxide (ATH)

and magnesium

hydroxide

Inorganic flame

retardants: graphite,

montmorillonite, silica,

carbon nanotubes and

nanofibers

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Flame Retardant Challenges

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Flame Retardant: Drivers & Challenges

Drivers

Challenges

Note: Size of the sphere identifies the impact on the market

Material

engineering

developments

Awareness

of public opinion

related to the

safety

requirements

Adoption of

stricter

environmental

and safety

regulations

High cost of

new type of

flame retardant

additivesNecessary

R&D

activities

Side effects

of flame

retardants

applications

Increasing

production

capacities of

products

utilizing flame-

retardants

Legislation and

following industrial

trends related to the

health and

envrironmental

issues

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Flame RetardantTechnology Accelerators

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Key Technology Accelerators

Impact of these accelerators will result in significant changes of flame retardant technologies.

Unique features of flame retardant nanomaterials

Ban on brominated

flame retardants

Increasing concern about the public safety issues

Stringent standard regulations

Miniaturisation and performance increase of

electronic devices require more efficient flame

retardants

Homogenous

phosphorous based FR

Technologies

Flame retardant

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Phasing Out Halogenated FR

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Flame retardant efficiency—similaras that provided by BFRs

Material compatibility--the substitute is compatible with the base polymer

Augmented by the rigorous standard regulations shift

toward green materials has been nearly finished in most of the industrial areas. However, there are other

materials, which could be added to the list of banned substances.

Effect on polymer properties--does not affectthe processing or aesthetic properties of

the base polymer negatively

Economically viable

More environment-friendly profile compared to

its predecessor

Halogen freeflame retardant

application

Halogen Free Flame Retardant Key Parameters

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FR R&D

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• Frost & Sullivan has recently profiled several latest developments, which took place within Flame Retardants areas of:

Inorganic

Flame

Retardants

Nitrogen

Containing

Flame

Retardants

Phosphorus

Flame

Retardants

Halogenated

Flame

Retardants

Development Areas in the FR Technology

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Nanocomposites

Development Areas in the FR Technology (cont.)

Inherently

Flame

Retardant

Polymers

Expandable

GraphiteIn tumescent

Systems

Boron

Containing

Flame

Retardants

Alternative flame retardant solutions

In industry there are few technically diverse flame retardant solutions.

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FR Technology Examples

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Inherent Flame Retardants

Clients prefers solutions with built in flame retardancy.

Research on phosphonate flame retardants is currently leaving universities and entering the commercial pilot plants.

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Nanocomposites Filler

�Oxides : �nano silica particles �metal oxides,

�Polyhedral Oligomeric Silsesquioxanes (POSS),

�Carbon Based Nanoparticles:�graphite, �single-walled carbon nanotubes (SWNT),�multi-walled carbon nanotubes (MWNT),�carbon nano fibers (CNF)

Nanofillers

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OPTIONS

CRITERIA

Multi-walled

Carbon nanotubes

based

Clay nanofiller

based

STRATEGIC

ATTRACTIVENESS

FINANCIAL

ATTRACTIVENESS

IMPLEMENTATION

DIFFICULTY

UNCERTAINTY

AND RISK

ACCEPTABILITY

(TO

STAKEHOLDERS)

Homogenous

FR based on

polymers

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Strategic Option Grid on Flame Retardant Composites

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Flame Retardant Nanocomposites

Flame retardant composite

Some nanoadditve applications requires technical experience.

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Drivers and Challenges Analysis of Flame Retardant Nanocomposites

Standard and law regulations

Positive effect of nanoadditive on flame retardant mechanical,

thermal and/or electrical properties

Increased durability of

nanocomposites

Potential cost saving with nanoaddtive applicaiton

Difficulties in additive dispersion Lack of

awarness of nanocomposite

benefits

Lack of understanding and

know – how of flame retardant nanocomposites fabrication

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Key Challenges of CNTs Nanocomposites Development

CNTs based FR

Technologies

Filler cost – nanocomposite performance trade off

Difficulties in CNTs homogenous dispersion

Health realted apprehension of CNTs usage

In some technical aspects lack of CNTs technology know-how

One of the currently developed and most promising FR technology utilizes Carbon Nanotubes filler.

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SWOT on CNTs Based Flame Retardant Composites

-Significant enhancement of flame retardancy of nanocomposite due to the synergistic effect.

-Increase in mechanical and physical properties of nano composite

-Prolonged lifetime of CNTs based products

-Foreseen increase of CNTs global production, and simultaneous price decrease

- High price of current flame retardants

- Continuous trend for introduction of stringent non-flammability regulations

-Global trend to avoid brominated FR.

-Early phase of research on CNTs usage as a flame retardant additive - Difficulties in dispersion of CNTs in the composite matrix

-False apprehension of potentially harmful impact of CNTs on health and environment.

-Possibility of CNTs replacement with clay nanofillers

-New inherently flame retardant materials

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Eco Lables

Customers are often guided by eco labels placed on products. Customers look for healthy and environmentally friendly solutions.

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