Recent developments in retardants for...
Transcript of Recent developments in retardants for...
Recent developments in flame retardants for sustainableflame retardants for sustainable fire safety solutions
Alex ZhangTechnical Service for AP Regiong
Requirements, Challenges and Innovations
19‐23 May 2013
Agenda
Great Lakes Solutions Overview
Greener Innovation Strategies
Emerald InnovationTM 3000 – polymeric Flame Retardant
Gl b l i lt h i l li t d th N Y k St kGlobal specialty chemical company listed on the New York Stock Exchange (“CHMT”)
Major markets served are energy & electronics, transportation, and i ltagriculture
Committed to global sustainability and engineering chemical solutions that meet our customers’ evolving needs
More than 4,300 employees worldwide
Manufactures in 31 countries and sells products in over 100 countries
Global headquarters in Philadelphia, Pennsylvania
Regional headquarters and shared service centers in S l il Sh h i Chi iddl b C iSao Paulo, Brazil; Shanghai, China; Middlebury, Connecticut; and Manchester, United Kingdom
Great Lakes Solutions, an Industry Leader
Electrical & El t i
Insulation & F it
AutomotiveFlame d
SE
S
INDUSTRIES SERVED
Electronics Furniture
FumigationEnergy: Oilfield & Mercury Control
Fine Chemical/ Pharmaceutical
Retardants
Brominated PerformanceB
US
INE
SS
Biocides Automotive TiresFumigation
BiocidesEnergy
Performance Products
KE
Y B
Mercury controlOther
Insulation &
FurnitureAuto
Fine Chem/Pharma
Mercury control
Greener innovation
Rapid growth in electronicsRO
WTH
V
ER
S
Furniture
Electrical & Electronics
Flame retarded energy efficient thermal insulation
Increased global fire safety standardsKE
Y G
DR
IV
The Sustainability Challenge for Flame Retardants
In today’s society, products are expected to be “green”be green
But, what is green?
Ideally, this includes:
− Total Carbon Footprintp
− Recyclability
− Green Chemistry & Engineering PrinciplesGreen Chemistry & Engineering Principles
− Chemical Hazard Classification and Risk Assessment
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Factors Affecting Flame Retardant Selection
Meet Fire Safety Standard
Environment & Human Health
Functional Requirements
End‐of‐Life Aspects
Economic FeasibilityAspects Feasibility
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Greener Innovation
How Do We Move Towards Environmentally Friendly, Sustainable FR Solutions?Sustainable FR Solutions?
Chemtura is applying a “Greener is Better” philosophyChemtura is applying a Greener is Better philosophy...
Polymeric FR is one of our Greener innovation direction
Toxicological and Regulatory Basis
Exemptions for polymers exist in REACh, TSCA and most other New Substance Notification regulations around the world
Under TSCA (40 CFR 723) details the polymer exemptions and exclusions and states that:
- In order to cause an adverse health or ecological effect, a chemical must first be absorbed by an organism, and
- Substance with a number average molecular weight above 1,000 g/mol are not readily absorbed through the intact digestive tract
This derived from the “Lipinski Rule of 5”1
- Is used in pharmacology to predict the biological activity of chemical compounds based on molecular weight and lipophilicitycompounds based on molecular weight and lipophilicity
- Suggests that a poor permeation of cell membranes occurs at molecular weights over 500
1. Lipinski, C.A.; Lombardo, F; Dominy, B.W. and Feeney, P.J. Adv Drug Del Rev 23: 3‐25, 1997
DRAFT Assessments – “Classical” BFRs
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DRAFT Assessments – Polymeric BFRs
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DRAFT Assessments – Phosphorus and Nitrogen FRs
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DRAFT Assessments – Inorganic FRs
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Great Lakes Solutions’ Polymeric and Reactive Flame Retardant Technologies a e eta da t ec o og es
Polymer Technology ProductsFi t ® CP44 HF
Polyamides PolybromostyreneFiremaster® CP44‐HFFiremaster® PBS64‐HW, PDBS‐80™
Polycarbonate, PBTBrominated Oligomer
Polybromostyrene
BC‐52™, BC‐58™, Firemaster® CP44‐HF
Firemaster® PBS64 HW PDBS 80™Polybromostyrene Firemaster® PBS64‐HW, PDBS‐80™
Unsaturated Polyesters Reactive Intermediate PHT‐4 ™, BA‐59P™
PHT 4 Diol™ PHT 4 Diol™ LVPolyurethane Reactive Intermediate
PHT‐4 Diol™, PHT‐4 Diol™ LV, Firemaster® 520
Polyolefins, HDPE, PPProprietary Polymeric
Emerald Innovation™ 1000Emerald innovation™ 3000St i PS HIPS ABS Emerald innovation 3000Styrenics, PS, HIPS, ABS
Epoxy Reactive IntermediatesBA‐59P™Emerald Innovation™ 2000
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Introducing Emerald Innovation™Our Next Generation of Flame Retardant ProductsOur Next Generation of Flame Retardant Products
Why Emerald Innovation™?Why Emerald Innovation ?Products are innovative, reliable and also minimize the impact on our environment and human health while maintaining superior performance and quality
S t i bl I ti Hi h P fSustainable, Innovative, High Performance Polymeric Flame Retardant for Polystyrene Foams
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Overview of Regulatory Action on HBCD
United Nations Protocols: UNEP, UNECEHBCD listing as POP under UNEP and UNECE
t d b d 2013 l 2014
Environment CanadaPublished Draft HBCD Screen Assessment in A t 2010expected by end 2013, or early 2014.
Time limited exemptions for use of HBCD in EPS and XPS are expected, up to 5 years.
Exemptions will only be granted “until
August 2010.
However, will follow UNEP and UNECE restrictions when implemented.
METI action on HBCD pending results ofExemptions will only be granted until alternatives are implemented”.
REACH August 2015 is the Sunset date for HBCD uses
METI action on HBCD pending results of an avian toxicity study
Study completed and final report being compiled and translated.g
without an approved authorization.
February 2014 is the deadline for applications for HBCD authorization.
A h i i d i i b h i i ill
An unfavorable result could lead to a regulatory restriction as early as Q1 2013.
US EPA: Design for the Environment Authorization decisions by authorities will depend on availability of an alternative.
projectEmerald InnovationTM 3000 one of only two alternatives to be assessed, and the only polymeric alternative
REACh timeline will likely govern phase out of HBCD
polymeric alternative.
The Value of Emerald Innovation™ 3000
The polymeric structure of Emerald Innovation™ 3000 renders it not readily bioavailable*, thus addressing the
Emerald Innovation™ 3000 is an efficient, sustainable l t f HBCD i i i i l difi ti t
environmental concerns that threaten the sustainability of many current products.
replacement for HBCD requiring minimal modification to current formulations or production processes.
Applicable fire safety standards covering polystyrene foam insulation can be achieved with Emeraldfoam insulation can be achieved with Emerald Innovation™ 3000.
Synergists commonly used for EPS and XPS production are compatible with Emerald Innovation™ 3000.
* Per criteria described in US Federal Register notice 40 CFR 723
Our strategy of greener innovation provides you with Our strategy of greener innovation provides you with proven, sustainable alternatives
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Emerald Innovation™ 3000
Property Emerald Innovation™3000
CAS# 1195978-93-8
Appearance white powder
Bromine, % 64
S f i i 0C 120Softening point, 0C 120
5% wt loss, 0C(Thermogravimetric Analysis (@ 10 0C/min under N2)
2620C
Emerald Innovation™ 3000 Flammability Performance Compared to HBCDp
Emerald Innovation™ 3000 demonstrates comparable thermal stability and fire retardant efficiency versus HBCD at similar bromine levels
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Flammability Performance
Emerald Innovation™ 3000 demonstrates comparable fire safety performance versus HBCD at similar bromine levels
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Comparison to Partially Aliphatic Bromine Source
Formulation % Br % SynergistJP‐JIS Fire Testing
Swiss Fire Testing (5.1)
HBCD 1.84 ‐ Pass Pass
Emerald Innovation™ 3000 1.75 ‐ Pass NM
FR1 1.78 ‐ Fail Fail
FR1 1.82 0.15 Fail Fail
FR1 1.82 0.3 Fail Fail
FR1 2.81 ‐ Fail Fail
FR1 2 88 0 15 Fail FailFR1 2.88 0.15 Fail Fail
FR1 2.84 0.3 Fail FailNM= Not MeasuredData provided by the Dow Chemical Company
FR1 = Tetrabromobisphenol A bis (2,3-dibromopropyl ether), a.k.a. PE-68™Synergist = An organic compound having labile C-C linkages capable of generating radicals in the early stages of ignition process which can reduce the molecular weight of the host polymer.
Ali h ti C B b d th k t ffi i i PS fAliphatic C‐Br bonds are the key to efficiency in PS foams
Only one half of the bromine in FR1 is aliphatic
FR1 is not effective at >50% higher load level
Results of Screening Versus Design for The Environment Assessment FrameworkEnvironment Assessment Framework
vL= very LowSource: Davis J W et al Strategic Approach Towards Developing More Environmentally
PolyFR = Emerald Innovation™ 3000vL= very LowL= LowvH= veryHighNE= no evidence
Source: Davis, J.W. et. al., Strategic Approach Towards Developing More Environmentally Sustainable Flame Retardants, 12th Workshop on Brominated and Other Flame Retardants, 2011
Persistent by Design, Required for Service Life & Stability
Low to Very Low in All Health and Environmental Effects
Stabilization of extruded polystyrene foam containing Emerald Innovation™ 3000containing Emerald Innovation 3000
Emerald InnovationTM 3000 is an efficient flame retardant for use in extruded l t f (XPS) d lik HBCD ill i t bili ti d ipolystyrene foam (XPS) and like HBCD will require stabilization during
extrusion.
A stabilizer formula consisting of hindered phenol (AO1) a high performanceA stabilizer formula consisting of hindered phenol (AO1), a high performance phosphite (P1), and an epoxy novalac resin (E1) provides the most effective stabilization package for Emerald Innovation 3000 in XPS foam.
This stabilizer system provides an excellent balance of color and molecular weight retention in XPS foam formulated with Emerald InnovationTM 3000.
Extensive Testing Conducted to Determine an Optimal Stabilizer Solution
Experimental Approach
Several combinations of primary and secondary antioxidants in combination with an epoxy novolac resin were evaluated.
All f l ti i l t d f lti l ti iAll formulations were run on a single screw extruder for multi‐pass evaluation in Polystyrene Nova PS1600 @ 200ºC.
Pellets from extrusion pass 1, 3 & 5 were set aside for melt flow and color determination on molded plaques.
The results show that a combination of AO1, P1 and E1 gives the best color and molecular weight retention in XPS foammolecular weight retention in XPS foam.
This optimized formulation is available from Chemtura as a non‐dust blend (NDB1).
NDB® technology offers superior compositional control, NDB® technology offers superior compositional control, better hydrolytic stability and improved industrial hygiene
Molecular Weight Stability
nsde
x, g/10m
inMelt F
low In
dM
Excellent retention of polystyrene molecular weight
Excellent Color Stabilityess Inde
xYello
wn
Color stability superior to neat polystyrene resin
Emerald Innovation™ 3000: Your Sustainable FR Solution for EPS and XPSThe polymeric nature of Emerald Innovation™ 3000 renders it more sustainable than other flame retardant alternatives. Emerald Innovation™ 3000 is the best
Your Sustainable FR Solution for EPS and XPS
choice when developing a sustainable product portfolio.
In EPS and XPS, Emerald Innovation™ 3000 demonstrates comparable efficiency at similar bromine content to HBCD.similar bromine content to HBCD.
Handling and processing of Emerald Innovation™ 3000 is comparable to HBCD.
U lik HBCD E ld I ti ™ 3000 d t i t f i l tUnlike HBCD, Emerald Innovation™ 3000 does not interfere in polystyrene polymerization chemistry, providing improved control of molecular weight during EPS production.
The high solubility of Emerald Innovation™ 3000 in styrene monomer allows for easy introduction into EPS production processes.
Emerald Innovation™ 3000 can be easily incorporated into a masterbatch for use inEmerald Innovation 3000 can be easily incorporated into a masterbatch for use in XPS.
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Conclusions
GREAT LAKES SOLUTIONS IS
COMMITTED TO GREENER INNOVATIONCOMMITTED TO GREENER INNOVATION
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CONCLUSIONSRecent introductions of new polymeric flame retardant platforms demonstrates the feasibility of sustainable flame t d tretardant
This approach applies to both halogenated and non‐halogenated flame retardants
Versatile cost‐effective approach across most polymerVersatile, cost effective approach across most polymer systems
G t L k S l ti id V til S t i blGreat Lakes Solutions provides Versatile, Sustainable Flame Retardant Solutions for a variety of applications
Acknowledgements d Th kand Thanks
Great Lakes Solutions Applications Research Laboratory
Dr. Subra Narayan
Harry Hodgen
Julie McKeown
Ken Bol
Applied Market Information Ltdpp