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Flame retardants: An Overveiw

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PEER REVIEWED TEXTILE POT POURI

Flame retardants: An overview


T. Grover , A. Khandual a , K. N. Chatterjee & R. Jamdagni
Deptt. of Fashion & Apparel Engg., Technological Inst. of Textiles & Science,
Bhiwani, Haryana

ABSTRACT
Many of the items we use on a daily basis, including textiles, electrical appliances, automobiles, and aircraft etc. are
now undergoing intense examination and scrutiny for their flammability properties. Flame retardants (FRs)
application play crucial protective function in saving life and property by reducing the overall fire risk associated
with using highly combustible raw materials in products such as textiles, clothing, composites, plastics etc. Flame
retardants are used to setback the spread of fires or delay the time of flashover enabling people to get sufficient
time to escape from the fire hazards. Recently, there has been an ever-growing demand for new flame retardant
product options; recognizing not only to ensure a favorable ecological profile but also a durable and cost effective
product. In this paper, we discuss various flame retardants types and their action mechanism.

Introduction Table 1: Cost of direct losses (in millions except


DUE to fires only, NFPA estimates that U.S. fire for Japan-billions) (28)
departments responded to an estimated 24,600 fires Country Currency Direct losses Percentage of GNP
started by lightning per year. These fires caused an
1989 1990 1991 1989-1991
estimated average of 12 civilian deaths, 47 civilian injuries
and $407 million in direct property damage per year (1). In Hungary Ft 0.12 (1986-88)
modern eras, we are approaching to unprecedented Spain Pta 0.12 (1984)
developments in the size and number of buildings, high Japan Y 450 520 720 0.14
riser, goods yard and methods of transport , carpeting, Finland FMk 880 880 0.17 (1988-89)
furnishings, appliances, oil and gas for heating etc. All United States US$ 9200 8200 10,000 0.17
Canada Can $ 1150 1250 1250 0.18
these increase the fire load in a modern society. Modern New Zealand NZ $ 120 150 125 0.18
fire-fighting techniques, equipment and building design Germany-west DM 4600 4350 0.19 (1989-90)
have reduced the devastation caused by fires. However, a Netherlands f 0.20 (1987-88)
high fuel load in either a residential or a commercial Austria Sch 0.21 (1979-80)
building can pay back even the best of building UK $ 1050 1300 1300 0,22
construction (7). New technologies, processes and new Switzerland SwF 675 0.23 (1989)
Denmark Dkr 2400 2100 2350 0.28
applications introduce new fire hazards (e.g., new ignition Sweden Skr 4000 3850 3600 0.28
sources such as welding sparks and short circuits) (6) France F 0.29 (1981-82)
which is becoming an alarming matter that is to be solved Norway Nkr 2450 1900 1750 0.31
on real time practically. A data assumed in this case, Belgium BF 26000 0.40 (1988-89)
approximately 3500 deaths per year in the United States. Fire losses include explosion losses following fires but exclude explosion loss
The major contribution occuring only from textile where no fire occurs, e.g. some acts of terrorism.
sources results in the largest percentage of deaths in
residential fires(2) .According to Wilmot(28), fire statistics economy. A overview of statically direct losses are given in
showed a high death toll and huge losses occurred for the Table 1 & Table 2.

Why FRs needed?


a
Corresponding Author, College of Engineering & Technology, lPrevent ignition
Bhubaneswar lDelay the spread of fires
lDelay the time of flashover to enable people time to escape
Queries and Responses: author.colourage@gmail.com lProtection of life

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Table 2: Fire Deaths (28) Table 3: Major Applications of flame retardants


other than Textiles
Country Adjusted figures (fire deaths)
Industry sector Applications
1989 1990 1991
Electrical Eng. & Wire and Cable
Austria 60 40 60 Electronics Consumer Electronics & back plates
Belgium 140 160 140 Office electronics housings & back plates
Canada 570 510 430 Printed circuits boards
Czechoslovakia 195 220 215 Appliances
Denmark 80 65 85 Transportations Applications
Finland 105 110 125
Motor vehicles Wire & cable
France 770 720 790 Seats
Germany - west 660 710
Hungary 300 320 350 Rail vehicles Compartment linings & coverings Insulation
Netherlands 95 80 90 Compartment interior
Norway 75 70 65 Seats
Spain 325 345 Aircraft Panels
Sweden 135 135 115 Carpets, flooring
Switzerland 30 25 30 Buildings Thermal insulation for roofs, facades, walls
UK 945 935 910 Sheeting's for roofs
US 5880 5640 4860 Floor coverings
Japan 1780 1860 1850 Ducting & conduit
New Zealand 45 35 35 Panels, linings, coverings

plastics and building materials. The other major applications


of flame retardants apart from textiles are outlined in Table 3.

Flame retardancy theory and mechanisms


FRs are being applied to the material to make them non-
inflammable or self extinguishing. In fact, they are of different
kinds that have to be applied on many materials that we come
in contact with everyday, such as building supplies, furniture,
plastic molding materials, clothing, mattresses, bedding, and a
variety of other materials. The principle of FRs is to decrease
its propensity to burn when subject to a heat source or open
Fig. 1: Flame retardants were credited with increasing escape
flame. As a consequence, deciding the suitable FR treatment
times for all 309 passengers from this jet (4)
for textiles is typically a complex process that largely depends
on the quality of fabric often demanded for the end use, and its
lProtection of property impact on the basic essential and desired properties of textiles.
and the environment Some of the good flame retardants application that associated
lPrevention of with good fabric quality can be ended up with an undesirable
immediate local effect during FR finishing of fabrics where some of the most
pollution to air and important textile properties may be sacrificed. They may cause
water detrimental effect on aesthetic properties such as luster,
lPrevention of lesser- stiffness, smoothness, handle and drape; processing
known long-ter m properties such as bulkiness, warp stability, washability, soiling,
environmental effects soil release, static electricity accumulation; tensile properties
such as modulus, tensile strength, elasticity, and pilling
It is estimated that
propensity; and physiological properties such as comfort,
escape times can be up to
odor, water absorption, heat of water absorption, leaching,
15 times longer when flame Fig. 2: Non-Flame retarded
& Flame Retarded (5) and health hazards (7).
retardants are present,
providing increased
Mode of action of flame retardancy
chances of survival (3). It is
depicted in the Fig. 3&4 how flame retardants help in saving In 1970s usage of flame retardants materials had gained
the life of personnel. momentum and they were being applied on flammable
There are number of FRs available that serves a vital materials that led to break the combustion cycle by affecting
purpose in protection against textile related fires and are used chemical or physical process occurring in one or both, the gas
throughout the world in various applications such as textiles, and condensed phases(8). The Function of Flame retardants

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are to intercept the combustion cycle by chemical and/or
physical ways in the solid, liquid or gas phase during the Flame retardant chemicals in the condensed phase cause a
reduction in the amount of gaseous combustibles produced
particular stages of burning (9-10). Flame retardants should
by altering the pyrolytic path. Instead, carbonaceous char,
inhibit or suppress the combustion process during particular
stages of the fire process e.g. heating, decomposition, ignition, water, and carbon dioxide are often produced (32,33). The inert
insulating material (e.g. char) serves to reduce the gases. The
or flame propagation (9).
char forms a heat and mass flow barrier which serves to
protect the fibre. Carbon is stabilized and prevented from
The physical action
turning into combustible gases. Dehydration and cross linking
Formation of a protective layer are two significant processes that play a role in flame retardants
which act via the condensed phase mechanism. Most of these
The chemicals should preferably be able to block the heat phenomenanon occurs in case of phosphorous based FR
transfer from the heat source and prevent oxygen flow to the compounds. These are both recognized to occur in cellulosics
flammable material. Also they prevent the supply of pyrolysis and synthetics. These flame retardants can cause a layer of
gases to the material surface. This mechanism can be observed carbon to form on the polymer surface. This can occur, for
in phosphorus compounds, silicon and boron compounds, example, through the dehydrating action of flame retardant
basic base additives and inorganic borates (9-10). generating double bonds in the polymer. Theses form the
carbonaceous layer by cycling and cross-linking. The chemical
Cooling effect reaction mechanism can be briefed as follows.
These can trigger the endothermic process which cools Preventive flame for protection, including the use of flame
down the substrate to a temperature so that ignition
temperature is not reached. Alumina Trihydrate (ATH) acts
this way (9-10).

Dilution effect
retardants, has been practised since ancient times. Some
These additives evolve non-flammable decomposition examples of early historical developments in flame retardants
gases and dilute the fuel in gas and solid phases, so that the are shown in Table 4 so that it can be in the gas phase in order
flammable gases concentration falls under the ignition limit to interfere with the combustion reactions in the flame.
and it cannot ignite [9, 10]. The most important chemical The personification of synthetic polymers earlier of this
reactions that flame retardant act in combustion process take century was of special concern, since the water-soluble
place in the solid and gas phase (9). inorganic salts used up to that time were of little or no
consumption in these largely hydrophobic materials.
Chemical Action Therefore, the development of polymer-compatible flame
The most relevant action is to suppress the combustion retardants was essential. During the Second World War, flame-
cycle in solid and gas phases. proof canvas awning for outdoor use by the military was
produced with a treatment of chlorinated paraffin and an
Reaction in gas (Vapour) phase insoluble metal oxide, mostly antimony oxide as a glow
The free radical mechanism of the combustion process Table 4: Early historical fire-retardant developments (11)
which takes place in the gas phase is interrupted by flame
retardant.The Exothermic process thus stopped, the system Development Date
cools down, and the supply of flammable gases is reduced and Alum used to reduce the flammability of wood About 450 BC
eventually completely suppressed. Polymers under pyrolysis by the Egyptians
can react with air resulting in chain branching reactions which
The Romans used a mixture of alum and About 200 BC
advance the combustion. The halogenated flame retardants vinegar on wood
interfere with the chain reaction by preventing hydroxide and
hydrogen free radicals from reacting with oxygen and carbon Mixture of clay and gypsum used to reduce 1638
flammability of theatre curtains
monoxide. Radicals are captured therefore disturbing the
exothermic oxidative flame chemical processes resulting in Mixture of alum, ferrous sulfate and borax 1735
used on wood and textiles by Wyld in Britain
the hindrance of combustion (32,33).
The reactions in the vapor phase mechanisms are as Alum used to reduce flammability of balloons 1783
follows . Gay-Lussac reported a mixture of (NH4)3PO4 1821
NH4Cl and borax to be effective on linen and
Hl+
l HX = H2 + X l
hemp
l HO + HX = H2O + X
l l
Perkin described a flame-retardant treatment 1912
l RH + X l
= R + HX
l
for cotton using a mixture of sodium stannate
Reaction in solid phase and ammonium sulfate

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resistor, together with a binder resin (13). After the war, non- retardants are of reactive components chemically built into a
cellulosic thermoplastic polymers became more and more polymer molecule. Additive flame retardants are incorporated
important as the basic fibres used profoundly for flame- into the polymer either prior to, during or (most frequently)
retardant applications. An archaistic example of the following Polymerisation. It is also reported that most FRs are
superiority of the non-cellulosic compounds is provided by from three main families of flame-retardant chemicals (29-31)
the diminished use of cotton fiber in children's sleepwear Inorganic: The main function of inorganic flame
since the inception of new standards. In 1971, cotton supplied retardants is to trigger the endothermic process for example
78% of the fibers used to produce children's sleepwear, aluminum trihydroxide, magnesium hydroxide, ammonium
whereas in 1973 it supplied less than 10% in the USA (US polyphosphate and red phosphorus. This group represents
EPA, 1976). about 50% by volume of the worldwide flame retardant
production due to its high stability, low cost. Antimony
Types of Flame Retardants trioxide is the most important chemical used as flame
Broadly FR compounds could be classified as organic or retardant synergists (18).
inorganic based, then can be sub classified as Phosphorous
and non-phosphorous based and so on depending upon the Halogenated
halogen groups present in it. According to KemI (1996), the Most of the members are based on chlorine and bromine.
flame retardants chemical types are classified as described in This group represents about 25% by volume of the worldwide
Fig. 3. production (18).
Flame retardants are also classified based on their
durability. For textiles, depending on their fastness to Organo phosphorus
laundering, flame retardants can be classified as non-durable ,
semi durable and durable. A distinction is made between They are primarily phosphate esters and represent about
reactive and additive flame retardants. Reactive flame 20% by volume of the worldwide production. Products
containing phosphor us,
chlorine and/or bromine are
also important. In addition,
nitrogen-based flame
retardants are used for a
limited number of polymers.

Inorganic flame
retardants
The influence of these
FRs arises due to its
superiority and effective
quality which helps to
achieve necessary
improvements in flame
retardancy. Metal hydroxides
form the largest class of all
f lame retardants used
commercially today by
common people and are
employed alone or in
combination with other
flame retardants to ensure
the desired results in terms
of safety level. Antimony
compounds are used as
synergistic co-additives in
combination with halogen
compounds, facilitating the
reduction in overall flame
retardant levels needed to
achieve a desired level of
flame retardancy. These
Fig. 3: Flame Retardants Chemical Types, KemI(1996) compounds may be used

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sole but are most commonly used with antimony trioxide to cellulosic material, e.g., cotton and paper. However, these
enhance other characteristics, for example, smoke reduction products are not preferred in case of cellulosic materials when
or afterglow extinguishing.. Inorganic phosphorus durable flame retardancy is required, since both are water-
compounds are primarily used in polyamides and phenolic soluble. Zinc borate, however, is water-insoluble and is
resins, or as components in intumescent formulations. Ionic profoundly used in plastics and rubber products. It is used
compounds have a very long history as flame retardants for either as a complete or partial substitution for antimony oxide
wool- or cellulose-based products. in PVC, nylon, polyolefin, epoxy, EPDM, etc. Zinc borate can
function as a flame retardant, smoke suppressant and anti-
Metal hydroxides arcing agent in condensed phase. Recently, zinc borate has also
Metal hydroxides function in both the condensed and gas been used in halogen-free, fire-retardant polymers.
phases of a fire by absorbing heat and slenderizing to release
their water of hydration. This process cools both the polymer Other metal compounds
and the flame and dilutes the flammable gas mixture. The very Molybdenum compounds are being used as flame
high concentrations (50 to 80%) required to impart flame retardants in cellulosic materials for many years and more
retardancy often adversely affect the mechanical properties of recently with other polymers, mainly as smoke suppressants
the polymer into which they are incorporated. Aluminum (see section 3.4 (6) ) . They appear to function as condensed-
hydroxide, also known as alumina trihydrate (ATH) is the phase flame retardants(15,21). Titanium and zirconium
largest volume flame retardant in use today. It decomposes compounds are used for textiles, especially wool (20). Zinc
when exposed to temperatures over 200°C, which limits the compounds, such as zinc stannate and zinc hydroxy-stannate,
polymers in which it can be incorporated. Magnesium are also used as synergists and as partial replacements for
hydroxide is stable to temperatures above 300°C and can be antimony trioxide.
processed into several polymers.

Antimony compounds Phosphorus compounds


Originally, Antimony trioxide is not a flame retardant, but it Red phosphorus and ammonium polyphosphate (APP) are
is used as a synergist. It is not only utilized in plastics, rubbers, used in various plastics. Red phosphorus was first investigated
textiles, paper and paints, but also 2-10% by weight, with in polyurethane foams and found to be very effective flame
organochlorine and organobromine compounds used to retardant. It is now used particularly for polyamides and
diminish the flammability of a wide range of plastics and phenolic applications. The flame retarding effect is due, in all
textiles (19). This is usually accomplished by release of halogen probability, to the oxidation of elemental phosphorus during
acids at fire temperatures and then it react with the antimony the combustion process to phosphoric acid or phosphorus
containing materials to form antimony trihalide and/or pentoxide. The latter acts by the formation of a carbonaceous
antimony halide oxide. These materials act both in the layer in the condensed phase. The formation of fragments that
substrate (condensed phase) and in the flame to suppress act by interrupting the radical chain mechanism is also likely.
flame promulgation. In the condensed phase, they promote Ammonium polyphosphate is mainly applied in intumescent
char conformation, which acts as a physical barrier to flame coatings and paints. Intumescent systems puff up to produce
and resists the volatilization of flammable materials. In the foams. Because of this characteristic they are used to protect
flame, the antimony halides and halide oxides, generated in materials such as wood and plastics that are combustible and
sufficient capacity, provide an inert gas blanket over the those like steel that lose their strength when exposed to high
substrate, thus it helps to avoid oxygen and preventing flame temperatures. Intumescent agents have been available
spread. These compounds commute the chemical reactions commercially for many years and are used mainly as fire-
occurring at fire temperatures in the flame, thus reducing the protective coatings. They are now used as flame-retardant
ease with which oxygen can combine with the uncertain systems for plastics by incorporating the intumescent
products. It is also propounded that antimony oxychloride or components in the polymer matrix, mainly polyolefins,
trichloride reduces the rate at which the halogen leaves the particularly polypropylene (6).
flame zone, thus increasing the probability of reaction with Other inorganic flame retardants
the reactive species. Antimony trichloride probably evolves
heavy vapours which form a layer over the condensed phase, Other inorganic flame retardants, including ammonium
stop oxygen attack and thus block the flame. It is also assumed sulfamate (NH4SONH2) and ammonium bromide (NH4Br),
that the liquid and solid antimony trichloride particles are used primarily with cellulose-based products and in forest
contained in the gas phase reduce the energy content of the fire-fighting (17).
flames by wall or surface effects (6).
Halogenated organic flame retardants
Boron compounds Halogenated flame retardants can be divided into three
Following the classification of boron compounds, Boric classes: aromatic, aliphatic and cycloaliphatic. The
acid (H3BO3) and sodium borate (borax) (Na2B4O7.10H2O) are effectiveness of halogen containing flame retardants increases
the two flame retardants those were being used primarily for in the order of F <CI <Br <I. Bromine and chlorine

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compounds are the only halogen compounds having polystyrene, which is primarily used to produce television
commercial significance as flame-retardant chemicals. cabinets. Secondary uses include ABS, engineering
Fluorine compounds are not used in practice because not only thermoplastics, polyolefins, thermosets, PVC and elastomers.
it doesn't interfere in combustion process but also expensive DeBDE is also widely used in textile applications as the flame
too and, except in special cases, are ineffective because the C-F retardant in latex-based back coatings (16). Hexa-bromo cyclo-
bond is too strong. Iodine compounds, although effective, are dodecane (HBCD), a major brominated cycloaliphatic flame
expensive and too lose bond to carbon (22,16). The brominated retardant, is primarily used in polystyrene foam. It is also used
flame retardants are much effective than the chlorinated types to flame-retard textiles. Some examples has been given in Table
because it releases HCl over a wider temperature range (22). 5.
With respect to processability, halogenated flame Chlorinated flame retardants
retardants vary in their thermal stability. In general,
aromatic brominated flame retardants are more Table 5: Typical FR examples with chemical constituency
thermally stable than chlorinated aliphatics, which
Type of chemical structure Example
are more thermally stable than brominated aliphatic.
Brominated aromatic compounds can be used in Several benzene rings Polybrominated diphenyl ethers
thermoplastics at fairly high temperatures without Decabromobiphenyl
the use of stabilizers and at very high temperatures 1,2-bis-(pentabromophenyl)
with stabilizers. The thermal stability of the
chlorinated and brominated aliphatic is such that, Tetrabromobisphenol acid Tetrabromophthalate diols and polyethers
with few exceptions, they must be used with thermal Tetrabromobisphenol A (TBBPA) TBBPA- derivatives
stabilizers, such as a tin compound. Halogenated
flame retardants are either added to or reacted with Oligomeric and polymeric compounds TBBPA-carbonate oligomer
the base polymer. Additive flame retardants are those TBBPA- based epoxy resin
that do not react in the application designated. There Poly-di and tribromostyrene
are a few compounds that can be used as an additive
in one application and as a reactive in another; tetra-bromo Chlorine-containing flame retardants belong to three
bis-phenol A is the most notable example. Reactive flame chemical groups: aliphatic, cycloaliphatic and aromatic
retardants become a part of the polymer either by becoming a compounds. Chlorinated paraffins are by far the most widely
part of the backbone or by grafting onto the backbone. The used aliphatic chlorine containing flame retardants. They have
choice of a reactive flame retardant is more complex than the applications in plastics, fabrics, paints and coatings(25). Bis
choice of an additive type. The development of systems based (hexachlorocyclopentadieno) cyclo-octane is a flame retardant
on reactive flame retardants is more expensive for the having unusually good thermal stability for a chlorinated
manufacturer, who in effect has to develop novel co-polymers cycloaliphatic. In fact, this compound is comparable in
with the desired chemical, physical and mechanical properties, thermal stability to brominated aromatics in some
as well as the appropriate degree of flame retardance (16-22). applications. It is used in several polymers, especially
Synergists such as antimony oxides are frequently used with polyamides and polyolefins for wire and cable applications. Its
halogenated flame retardants. principal drawback is higher quantities are needed for
achieving required flame retardancy compared to brominated
Brominated flame retardants flame retardants (16).
These FRs have the highest market share because of their
good technical and performance properties. It can be sub- Organo-phosphorus flame retardants
divided into several classes based on the following types of One of the principal classes of flame retardants used in
chemical structure in table- 5 .Bromine-based flame retardants plastics and textiles is that of phosphorus, phosphorus-
are highly brominated organic compounds with a relative nitrogen and phosphorus-halogen compounds. Phosphate
molecular mass ranging from 200 to that of large molecule esters, with or without halogen, are the predominant
polymers. They usually contain 50 to 85% (by weight) of phosphorus-based flame retardants in use.
bromine (22). The highest volume brominated flame retardant For textiles, phosphorus-containing materials are by far the
in use today is tetrabromobisphenol A (TBBPA) (24) followed most important class of compounds used to impart durable
by decabromodiphenyl ether (DeBDE) (23). Both of these flame resistance to cellulose. These textiles flame retardant
flame retardants are aromatic compounds. The primary use of finishes usually also contain nitrogen or halogen, or sometimes
TBBPA is as a reactive intermediate in the production of both (17-20).
flame-retarded epoxy resins used in printed circuit boards (24).
A secondary use for TBBPA is as an additive flame retardant in Non-halogenated compounds
ABS systems. DeBDE is the second largest volume Although many phosphorus derivatives have flame-
brominated flame retardant and is the largest volume retardant properties, the number of those with commercial
brominated flame retardant used solely as an additive. The importance is limited. Some are additive and some reactive.
greatest use (by volume) of DeBDE is in high-impact The major groups of additive organo-phosphorus

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compounds are phosphate esters, polyols, phosphonium linker and or binder copolymer that makes the FRs more
derivatives and phosphonates. The phosphate esters include resistant to common weathering conditions and exposures.
trialkyl derivatives such as triethyl or trioctyl phosphate, triaryl They too produce less or no obnoxious gases while burning.
derivatives such as triphenyl phosphate and aryl-alkyl
derivatives such as 2-ethylhexyl-diphenyl phosphate. The
flame retardancy of cellulosic products can be improved References
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