Sustainability up and down the flame retardant supply chain
Lumina CEO Brian Hanrahan discusses the often unseen full impact of flame retardant materials and explores new technology alternatives
Flame retardant ( FR ) regulation is a highly charged topic , most often focused on potential health and environmental effects downstream . Halogenated FRs , some non-halogenated phosphorus products and other synergist chemistries all have the potential to harm human and aquatic life . Whilst these effects get the most attention , consumers and ESG advocates must also investigate the origin of materials and their full cradle-to-grave impact before making sustainability conclusions . Factors such as product origin , supply chain efficiency , and synthesis and processing methods all have an equally large human impact . Looking up and down the supply chain can not only give a better understanding of total life cycle impact , it can also help identify more reliable and economic supply sources .
Upstream impact of ATH
Aluminium trihydroxide ( ATH ) and magnesium dihydroxide ( MDH ) are often seen as strong natural choices for non-halogenated FR . ATH has not been identified with direct harmful health effects , but its manufacturing process has .
For over 130 years , aluminium has been produced through the energyintensive Bayer process , in which bauxite ore is pressure-heated to 150- 200 ° C in a caustic leach . The aluminium is dissolved and then precipitated as ATH which can then be ground or purified and precipitated again into higher grade ATH products . The process creates of red mud , a toxic , caustic slurry with complex chemistry . For every tonne of ATH , 1.5 tonnes of red mud are created at over 60 sites worldwide . This waste has historically been stored in
Lumina ’ s site in Greenland
Figure 1 - FR supply chain life cycle analysis
Supply chain step |
Raw material origin / Processing |
FR material manufacturing |
Plastic compounding |
Final part conversion |
Human interaction with part |
Current risk |
ATH red mud ; conflict zone minerals ( including Russia ) |
Co-products for metal and fertiliser ; energy and thermal processing ( CO 2 ) |
Dust exposure ; formulation complexity ; logistics optimisation |
Total FR loading level ; impact on other properties including cost |
Human and aquatic risk from halogenated FR , irritant from phosphates , etc . |
Sustainable improvement |
First Bauxite ( Guyana ) and Lumina ( Greenland ) mineral FR ’ s |
Natural minerals with minimal processing ; local supply |
Highly filled masterbatches ; natural synergists |
Blends of natural and synthetic FR , total formulation optimisation |
Partial to full replacement with natural and treated minerals |
58 SPECIALITY CHEMICALS MAGAZINE ESTABLISHED 1981