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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.
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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.
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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
through the application of phosphonium salts. The flame-
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