FLAME RETARDANTS
Supply chain disruptions from COVID and the war in Ukraine , along with increased demand , have led to massive price escalations for phosphate materials . Spot prices for phosphoric acid in Europe tripled from € 850 / tonne in March 2021 to € 2,480 / tonne in March 2022 . Identifying FRs that do not rely on volatile chemical prices , such as natural minerals , can help stabilise supply chains . Another factor of co-dependence involves the aluminium market . Over the last 20 years , most integrated aluminium producers have divested their chemical business activities and these stand-alone alumina processors have closed their Bayer refineries . This has resulted in alumina chemical producers having to source ATH from large , metal-focused refineries . In the US , aluminium metal producers have curtailed production at their high energy , inefficient , legacy plants and shifted metal production to lower energy cost locations like Iceland and Dubai . Given the global market dynamics , with a focus on aluminum metal production , 90 % of which is from bauxite ), this has led to a shortage of ATH for chemical applications . First Bauxite is again unique in that its material is not used in the metallurgical world , allowing it to operate independently of the commodities market .
Multi-additive solutions
Another way to reduce the environmental impact of FRs is to reduce total usage through formulation . One complexity here is the different modes of FR , including char formation , water release , foaming , anti-drip , intumescence and smoke suppression . An optimal FR package may use two or three ingredients to minimise total loading or cost . For example , phosphorus chemistry can be supplemented with a PTFE anti-drip agent to yield V0 rating with the lowest loading level . Sadly , if these additives come from different vendors , you may not get honest feedback on potential synergies . Keep multiple industry touch-points
‘ Red mud ’ is an unwanted by-product of ATH processing
and look for unbiased data and presentations from neutral sources . Test new formulas and developments on a regular basis to keep your supply chain in check . Having multiple additives approved in advance can help you flex when pricing or availability risk a current formula .
Delivery optimisation
Another key component of lifecycle analysis is looking at the sourcing and distribution of additives . Foreign trade will likely be required for some FR ingredients , but can lead to disruptions , as seen in the last 12 months . As a benefit though , water transport has over a six times benefit in carbon emissions vs . road traffic . Using global sources of raw material with local processing can give the best combination of consistent global supply with optimised freight and local inventory . The delivery format also has an impact on the health of employees compounding or otherwise integrating the FR into formulations . FR dust from product handling , transferring , dumping or feeding , can lead to potential health risks . A novel solution to diverse delivery problems is Celestial Materials ’ highlyfilled masterbatches . These additive packages contain one or more FR additives fully embedded into highlydispersible plastic pellets at loading levels up to 96 %. In addition to eliminating dust , highly-filled masterbatches also yield other sustainability benefits . When compounding , highly-filled concentrates can more than double capacity through increased feed rates , reduced torque and lower operating temperatures . This is a dramatic shift in productivity , which replaces capital expenditures with variable cost while improving energy usage and carbon footprint . In some cases , these concentrates can be blended at the press to eliminate the expense and logistics of compounding altogether . Finally , clean-outs and change-overs occur much more rapidly with concentrates , further enhancing efficiency and productivity .
Outlook
FR selection is a challenging process which requires engagement across multiple disciplines . For companies who truly value ESG , looking upstream at the origin , processing and distribution of raw material is just as important as looking at downstream health impacts . Fortunately , there are new options for FR additives based on more natural ingredients with minimal processing and environmental impact . Companies must consistently explore options from multiple vendors to ensure they can adapt to rapidly changing pricing , availability , performance requirements and regulatory requirements . •
Brian Hanrahan
CEO
LUMINA SUSTAINABLE MATERIALS k + 1 805 453 5187 J brian @ lumina . gl j www . lumina . gl
60 SPECIALITY CHEMICALS MAGAZINE ESTABLISHED 1981