DEROCA

Development of safe and eco-friendly flame retardant materials based on CNT co-additives for commodity polymers

 Partecipanti

Mappa

 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

 Obiettivo del progetto (Objective)

'Currently, best flame retardant formulations are still often based on halogenated flame retardants (FR). Those halogneted FR are supsected to endcrine disrupters when leaching from the material and produce toxic fumes and acids (HBr, HCl, organoirritants, PCDD/Fs etc.). DEROCA project aims at (i) developing and introducing new safer and more eco-friendly FRs through exploiting the synergistic effect of carbon nanotubes with phosphorus based flame retardants and other new promising additives in intumescent or carbon crust formation systems by promoting a more efficient/cost competitive solution; (ii) developing small scale test methods and models to predict full end product standard scale test results based on small scalte tests. The approach will be multifaceted: (i) to better understand and promote interactions between CNT and different (FR) additives; (ii) to develop FR applications for five final products which represent large volumes of commodity polymers, i.e. automotive industry, wire and cable, industrial packaging and foam; (iii) to demonstrate and to assess fire performance of end-products, including fire toxicity; (iv) to develop models for the prediction of fire classification of materials based on small scale tests; (v) to introduce small scale test methods and models developed into international standardization; (vi) to assess the mechanical and other product specific essential properties of the FR polymer; (vii) to assess toxcicity and environmental impact of the FRs developed both in the production chain and in the end use product; (ix) to assess the overall envrionmental impact of the Frs developed FRs through LCA.'

Introduzione (Teaser)

Halogenated flame retardants (HFRs) are commonly used in consumer products but they have raised concerns due to their persistency, bioaccumulation on living organisms and their potential toxic effects on human health. In this project, scientists are developing an eco-friendly alternative to the halogenated agents commonly used that are subject to ever-stricter regulation due to potential toxicity.

Descrizione progetto (Article)

The EU is funding the http://www.deroca.eu/ (DEROCA) project aiming at developing and introducing new safer and more eco-friendly FR through exploiting the synergic effect of carbon nanotube (CNT) with phosphorus based flame retardants and other new promising additives in intumescent or carbon crust formation systems by promoting a more efficient/cost competitive solution; developing small scale test methods and models to predict full end product standard scale test results based on small scale tests and assessing the safe use and absence of toxicity of the new FR materials in production, use and fire situations. Target applications are consumer products, like stadium chairs, corrugated pipes for protecting electrical cables from crushing, wires and cables sheaths, insulation foams, and industrial fan blades for ventilation and air conditioning systems.

During the first 18 months, notable achievements were done regarding the understanding of the interactions between CNT and different FR additives. Although some early results were not very convincing regarding the ability of CNTs to prevent fire, new approaches have been developed to use the best of the CNTs actions. Cone calorimeter and UL-94 results showed an improved and strengthened charring effect, a drastic reduction of dripping and flame spread rate as well as an additional synergist effect with phosphorus based flame retardant. It has led to solutions for fire resistant thermoplastics. In particular, a halogen-free flame retardant (HFFR) PP which passes UL 94 V0 @ < 2 mm was developed.

The European Commission's Construction Products Regulation (CPR) has recently been expanded to include cables and wires, which must meet the new EN 50399 standard for fire performance. Researchers have developed a small-scale test of vertically mounted cables to accurately reproduce the behaviour of the cable in the EN 50399 test apparatus. Together with a pyrolysis model of the small-scale test, designers will now have a way to screen new materials for compliance.

In addition, promising results were obtained regarding the characterisation of smoke production from burning polymers under different fire conditions. It will be validated with comprehensive data from polymers with and without fire retardants. In the end, this will be a valuable tool to assess fire toxicity, inhalation hazards and heat transfer.

Finally, researchers are developing a life-cycle assessment for the fire retardants to assess environmental impact from cradle to grave. A questionnaire completed by partners provides insight on raw materials, use of raw materials, and energy during production, emissions and waste handling.

DEROCA's new products, tests and simulations are expected to speed the adoption of halogen-free flame retardants in a variety of commodity polymer products. Beneficiaries include the European stakeholders of the value chain of flame retarded products (from raw materials producers to end users via compounders and injection molders), EU academic experts in fire toxicity but especially the EU citizens who will be using safer, less expensive and more eco-friendly products.