The co-pyrolysis of flame retarded high impact polystyrene and polyolefins

The co-pyrolysis of brominated high impact polystyrene (Br-HIPS) with polyolefins using a fixed bed reactor has been investigated, in particular, the effect that different types of brominated aryl compounds and antimony trioxide have on the pyrolysis products. The pyrolysis products were analysed using FT-IR, GC–FID, GC–MS, and GC–ECD. Liquid chromatography was used to separate the oils/waxes so that a more detailed analysis of the aliphatic, aromatic, and polar fractions could be carried out. It was found that interaction occurs between Br-HIPS and polyolefins during co-pyrolysis and that the presence of antimony trioxide influences the pyrolysis mass balance. Analysis of the Br-HIPS + polyolefin co-pyrolysis products showed that the presence of polyolefins led to an increase in the concentration of alkyl and vinyl mono-substituted benzene rings in the pyrolysis oil/wax resulting from Br-HIPS pyrolysis. The presence of Br-HIPS also had an impact on the oil/wax products of polyolefin pyrolysis, particularly on the polyethylene oil/wax composition which converted from being a mixture of 1-alkenes and n-alkanes to mostly n-alkanes. Antimony trioxide had very little impact on the polyolefin wax/oil composition but it did suppress the formation of styrene and alpha-methyl styrene and increase the formation of ethylbenzene and cumene during the pyrolysis of the Br-HIPS.     

The effect of different impact modifiers in halogen-free flame retarded polycarbonate blends - I. Pyrolysis

In this first of two papers, the thermal decomposition of bisphenol A bis(diphenyl phosphate)-flame retarded polycarbonate (PC) blends with different impact modifiers was studied. The impact modifiers were an acrylonitrile-butadiene-styrene (ABS), a poly(n-butyl acrylate) (PBA) rubber with a poly(methyl methacrylate) (PMMA) shell and two silicone-acrylate rubbers consisting of PBA with different amounts of polydimethylsiloxane (PDMS) and different shells (PMMA and styrene-acrylonitrile, SAN). The focus of this work was to study the impact of the acrylate and silicon-acrylate rubbers with respect to pyrolysis and flame retardancy in comparison to common ABS. Thermogravimetry (TG) was performed to investigate the pyrolysis behaviour and reaction kinetics. TG in combination with FTIR identified the pyrolysis gases. Solid residues were investigated by FTIR-ATR. PC/ABS shows two-step decomposition, with PC decomposing independently from ABS at higher temperatures. Pure acrylate rubber destabilises PC due to interactions between the rubber and PC, which leads to earlier decomposition of PC. Using silicone-acrylate rubbers led to similar results as PC/ABS with respect to pyrolysis, reaction kinetics and analysis of the solid residue; hence the exchange of ABS for the silicone-acrylate rubbers is possible.     

Study on intumescent flame retarded polystyrene composites with improved flame retardancy

The flame retardancy and thermal stability of ammonium polyphosphate/tripentaerythritol (APP/TPE) intumescent flame retarded polystyrene composites (PS/IFR) combined with organically-modified layered inorganic materials (montmorillonite clay and zirconium phosphate), nanofiber (multiwall carbon nanotubs), nanoparticle (Fe₂O₃) and nickel catalyst were evaluated by cone calorimetry, microscale combustion calorimetry (MCC) and thermogravimetric analysis (TGA). Cone calorimetry revealed that a small substitution of IFR by most of these fillers (≤2%) imparted substantial improvement in flammability performance. The montmorillonite clay exhibited the highest efficiency in reducing the peak heat release rate of PS/IFR composite, while zirconium phosphate modified with C₂₁H₂₆NClO₃S exhibited a negative effect. The yield and thermal stability of the char obtained from TGA correlated well with the reduction in the peak heat release rate in the cone calorimeter. Since intumesence is a condensed-phase flame process, the MCC results showed features different from those obtained from the cone calorimeter.     

Preparation and combustion properties of flame retarded polypropylene-polyamide-6 alloys

In this work, polypropylene (PP) and polyamide-6 (PA6) alloys were prepared by blending PP and PA6 or nano-PA6 while using a compatibiliser such as maleic anhydride-g-polypropylene (MAPP). Their physical structures were characterized by Hitachi X650 scanning electron microscope (SEM) and transmission electron microscopy (TEM). An intumescent flame retardant (IFR) was added to the PP/PA6 alloys and their flammability behaviour was evaluated using cone calorimeter and real time Fourier transform infrared (FTIR). The probable mechanisms are discussed.     

Controlled pyrolysis of polyethylene/polypropylene/polystyrene mixed plastics with high impact polystyrene containing flame retardant: Effect of decabromo diphenylethane (DDE)

The pyrolysis of polyethylene(PE)/polypropylene(PP)/polystyrene(PS) mixed with high impact polystyrene (HIPS-Br) containing decabromo diphenylethane (DDE) as a brominated flame retardant with antimony trioxide as a synergist was performed under controlled temperature programmed pyrolysis (two steps) conditions to understand the decomposition behaviour and evolution of brominated hydrocarbons from flame-retardant additives. The liquid products were extensively analyzed by gas chromatographs equipped with FID, ECD, MSD, TCD, AED and FT-IR. The solid residue samples were analyzed by powder X-ray diffraction and combustion followed by ion-chromatography. The controlled pyrolysis of PE/PP/PS/HIPS-Br significantly affected the decomposition behaviour of HIPS-Br and subsequently the formation of decomposition products. GC/ECD analysis confirmed that the brominated hydrocarbons were concentrated in step 1 liquid products leaving less brominated hydrocarbons in the step 2 liquid products, similar to the decabromo diphenyl ether flame retardant containing mixed plastics. The yield of liquid products in step 1 from 3P/DDE-Sb(5) was 5 wt% and from 3P/DDE-Sb(0) was 2.4 wt%. The presence of antimony in the DDE containing plastics affected the yield of liquid, gas and residue products. ECD analysis showed that the presence of antimony increased the Br containing hydrocarbons and step 1 has 3-4 times higher brominated compounds than step 2 hydrocarbons in both the samples.     

(Photo)oxidative degradation and stabilization of flame retarded polymers

Flame retarded polymer formulations are mainly used in long-term applications whereas antioxidants, light stabilizers and co-additives provide the requested lifetime of plastic materials. However many flame retardants influence the oxidative and photooxidative stability of polymers often in a negative way resulting in early failure and loss in value. Moreover insufficient (photo)oxidative stability of the flame retardant itself may reduce the flame retardance performance over time. Therefore, there is a need to develop adjusted stabilizer systems considering the type of flame retardant, the polymer substrate and the intended application. Therefore, the influence of flame retardants on the (photo)oxidative stability of selected polymers is reviewed and strategies to extend the lifetime of flame retarded polymers are provided. In addition, the specific requirements of the stabilization of nanocomposites as potential flame retardant components are covered.     

Pyrolysis of mixed polyolefins in a fluidised-bed reactor and on a pyro-GC/MS to yield aliphatic waxes

Polyolefins (PE, PP and PS) were pyrolysed in a fluidised-bed reactor on kilogram scale at 510°C. Pyrolysis products were analysed with GC, GC/MS and other methods. It was shown that valuable products, mostly aliphatic waxes, are received from polyolefins. It was also investigated if mixtures of different polyolefins (PE, PP, PS) interact with each other in fluidised bed pyrolysis yielding different pyrolysis products than received from the pure, individual polyolefins. The same polymer mixtures were also analysed using a pyro-GC/MS-device.     

Studies of degradation enhancement of polystyrene by flame retardant additives

Experimental methods as well as thermodynamic modeling techniques were utilized to explore potential gas and condensed-phase contributions of various flame retardant (FR) additives with polystyrene polymer. FR additives investigated include hexabromocyclododecane (HBCD), triphenyl phosphine oxide (TPPO), triphenyl phosphate (TPP), triphenyl phosphine sulfide (TPPS), and sulfur. Flame studies of fundamental FR activity were also employed using molecular beam mass spectrometry analysis of FR active species directly in a flame system. The flame studies show direct evidence for active bromine (HBr, Br) species for HBCD and active phosphorous species (HPO₂, PO, PO₂ HPO₃) species for TPPO and TPP which provide high potential for gas-phase activity for these FR additives. Various experimental measurements were also done to assess the degradation species and the degree of degradation of polystyrene by the FR additives. These studies support enhanced degradation of the base polystyrene polymer by the FR additive as a major pathway for condensed FR activity for HBCD and sulfur FR additives. Phosphorous based structures appear to show little enhancement of polystyrene degradation.     

An innovative process for mass production of multi-wall carbon nanotubes by means of low-cost pyrolysis of polyolefins

An innovative process for a mass production of multi-wall carbon nanotubes (MWCNTs) by means of pyrolysis of virgin or recycled polyolefins is described. The technique uses solid-gas fluidised bed reactors, continuously operated under conditions which allow high heating rates of the polymers, high heat and material exchange coefficients and a reliable control of residence times in the reactor. The obtained MWCNTs have been characterized by TGA, SEM and TEM microscopy as well as X-ray diffractometry and Raman spectroscopy. The results demonstrate that the proposed process allows the production of MWCNTs compatible with most of the already known applications, in large quantities and at low cost. This makes extremely wider the field of possible applications of these nanostructured materials.     

A comparison of different analytical techniques (energy dispersive X-ray fluorescent spectrometry, bomb calorimetry combined with ion chromatography and inductively coupled plasma-optical emission spectrometry) for the determination of the bromine and antimony content of samples

In recent years, there has been intensive research into the use of pyrolysis to process toxic plastics from waste electrical and electronic equipment (WEEE). During pyrolysis, the fate of the bromine and antimony content of the plastics is critical therefore, new and improved analytical techniques for analysing these elements in the pyrolysis products are being sought. In this work, the effectiveness of energy dispersive x-ray fluorescent spectrometry (EDXRFS) for the determination of bromine and antimony content of pyrolysis oils from waste electrical and electronic equipment have been tested. Samples were obtained by the pyrolysis of brominated high-impact polystyrene (Br-HIPS) and brominated acrylonitrile-butadiene-styrene (Br-ABS) at temperatures from 360 to 440 °C. The concentration range of both the bromine and antimony in the samples was very broad (0.05-17.94 wt% and 0.03-8.54 wt% respectively). The results from EDXRFS to those of more traditional and time consuming methods; bomb calorimetry combined with ion chromatography (EPA method 5050) for bromine and acid digestion combined with inductively coupled plasma-optical absorption spectrometry for antimony were compared.Based on our measurements, different statistical parameters were calculated for each analytical technique, which demonstrated that EDXRFS had been successfully applied to the determination of bromine and antimony concentration in the pyrolysis oils of Br-HIPS and Br-ABS. Errors resulting from matrix effects did occur, in particular correlations were found between the nitrogen content of the samples and the difference in bromine and antimony measured by EDXRFS and other methods (ion-chromatography and ICP-OES). However, these differences were found to be statistically insignificant, so we could conclude that EDXRFS is a suitable technique for analysing the bromine and antimony content of pyrolysis oils.     

A quantitative study of carbon monoxide and carbon dioxide evolution during thermal degradation of flame retarded epoxy resins

Thermogravimetric analysis (TGA) combined with infrared analysis of the evolved gases analysis (EGA) has been used to study the thermal degradation behaviour of epoxy resin both in air and nitrogen. The mass loss as a function of temperature has been correlated with the evolution of carbon monoxide (CO) and carbon dioxide (CO₂), and oxygen consumption as measured using an oxygen analyser. An analytical technique has been developed to quantitatively measure the carbon monoxide and dioxide gases evolved. The effect of a range of flame retardants containing phosphorus, nitrogen and halogen elements on CO and CO₂ evolution during thermal degradation of flame retarded epoxy resins has also been observed.     

Further considerations of the sources of the volatiles from pyrolysis of polystyrene

Formation of the radical precursor to trimer (T) during pyrolysis of polystyrene features a 1,5-hydrogen shift. However because 1,3-shift is so much slower, the sources of the less abundant dimer (D) and tetramer (Te) remain unclear. While we and others have proposed addition of small radicals to olefinic polymer end-groups as a route to oligomer precursor radicals, others recently suggested that such addition is also too slow and proposed a third alternative: 1,7-shift followed serially by 7,3-shift to give the precursor for D. Although considerable evidence suggests that 1,7-shift would be much slower than 1,5-shift, this alternate kinetic model assigned them as comparably rapid. We apply a computational method to predict initial product distributions based on estimated, and empirically varied, propagation rate constants for 1,x-shift, β-scission, hydrogen transfer, and addition radical steps. The addition mechanism successfully predicted the relative amount of D but systematically underestimated Te. This deficiency could be removed by empirical inclusion of a small amount of 1,7-shift, although the other literature evidence still causes this to remain a questionable hypothesis.     

Investigation of melamine and DOPO-derived flame retardants for the bioplastic cellulose acetate

In order to identify suitable flame retardant additives for the eco-friendly polymer cellulose acetate (CA), high-melting derivatives of the known flame retardant 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) were combined with the thermoplastic CA and the combustion properties were tested. CA mixtures with bis-phosphonamidates (EDA-DOPO and PIP-DOPO) showed distinct flame retardation effects and a reduction of peak heat release rates (PHRR) by up to 18%. CA mixtures with MDOP, a melamine salt of DOPA (an oxidation product of DOPO), also showed considerable effects and a reduction of PHRR by up to 27%. While producing more smoke than pure CA and CA plus melamine, owing to its aromatic component, MDOP was superior to the CA mixtures with DOPO, EDA-DOPO and PIP-DOPO in this regard. The mixture of CA with melamine gave rise to a distinctly reduced formation of toxic CO and smoke when compared with pure CA. Thus, these additives can be considered for future applications of CA-based polymers with enhanced flame protection.     

气相色谱-质谱法测定玩具中的4种阻燃剂

建立了玩具中三(2-氯乙基)磷酸酯、磷酸三邻甲苯酯、2,2′,4,4′,5-五溴联苯醚、2,2′,3,3′,4,4′,6,6′-八溴联苯醚等4种阻燃剂的气相色谱-质谱分析方法。玩具样品以V(正己烷):V(二氯甲烷)=1:1混合溶液为提取溶剂,超声提取30min,提取液以DB-5HT石英毛细管色谱柱(15m×0.25mm×0.10μm)分离后进行选择离子监测模式下的定性及定量分析。4种阻燃剂的定量限为0.1mg/kg,在低、中、高3个添加水平范围内,4种阻燃剂的平均回收率为93.5%～97.3%,相对标准偏差在2.4%～4.1%之间。     

The effect of different impact modifiers in halogen-free flame retarded polycarbonate blends - II. Fire behaviour

In this second of a series of two papers, the fire behaviour of halogen-free flame retarded polycarbonate (PC) blends with different impact modifiers was studied. The impact modifiers were acrylonitrile-butadiene-styrene (ABS), a poly(n-butyl acrylate) rubber (PBA) with a poly(methyl methacrylate) (PMMA) shell and two silicone-acrylate rubbers consisting of PBA with different amounts of polydimethylsiloxane (PDMS) and different shell materials (PMMA and styrene-acrylonitrile, SAN). The flame retardant was bisphenol A bis(diphenyl phosphate) (BDP). Flammability was determined by LOI and UL 94. The burning behaviour under forced flaming conditions was studied by cone calorimeter under different external irradiations and by pyrolysis combustion flow calorimeter measurements. The exchange of ABS with the pure acrylate rubber worsened flammability, while similar results were obtained in cone calorimeter measurements. The exchange of ABS with the silicone-acrylate rubbers is promising, particularly with higher amounts of PDMS. In flammability tests strongly enhanced LOI values were obtained and therefore silicone-acrylate rubbers look like promising alternatives for ABS.     

Fire behavior of flame retarded unsaturated polyester resin with high nitrogen content additives

The novel flame retarded unsaturated polyester resins have been developed and prepared by introduction of high nitrogen content additives into the polymer matrix in order to verify their effectiveness in the formation of swollen carbonaceous char inhibiting the burning process of the polymer. The intumescent flame retardants (IFRs) based on mixture or metal complex were developed and characterized by particle size distribution, Fourier-transform infrared spectroscopy (FTIR), nuclear magnetic resonance (NMR), powder X-ray diffraction (XRD), elemental analysis (CHN) and thermogravimetric analysis (TGA). The evaluation of the efficiency of IFRs addition on the flammability and smoke emission of the unsaturated polyester resins (UP) was carried out using the fire hazard (UL-94), limiting oxygen index (LOI) and cone calorimeter (CC) tests, as well as smoke density chamber tests. The volatile compounds evolved during the burning of materials were determined using a steady state tube furnace and a gas chromatograph with mass spectrometer. Furthermore, the prepared materials were subjected to differential scanning calorimetry (DSC), thermogravimetric analysis and water resistance tests. The mechanical properties of the materials were investigated using Shore D hardness and dynamic mechanical thermal analysis (DMA). The structural evaluation of the manufactured materials and samples after the cone calorimetry tests was carried out using scanning electron microscopy (SEM). It was found that the incorporation of new intumescent flame retardants led to the formation of carbonaceous char layers’ inhibiting the decomposition process and limiting the smoke emission. The most promising results were obtained for the resin containing complex designated as ZN3AT, for which the highest reduction in maximum values of heat release rate (419 kW/m²) compared to unmodified polymer (792 kW/m²) were recorded. Apart from that, the prepared intumescent flame retardants affect the cross-linking process as well as the thermal and mechanical properties of the UP.     

Synergistic effect of carbon nanotubes and decabromodiphenyl oxide/Sb2O3 in improving the flame retardancy of polystyrene

Brominated flame retardant polystyrene composites were prepared by melt blending polystyrene, decabromodiphenyl oxide, antimony oxide, multi-wall carbon nanotubes and montmorillonite clay. Synergy between carbon nanotubes and clay and the brominated fire retardant was studied by thermogravimetric analysis, microscale combustion calorimetry and cone calorimetry. Nanotubes are more efficient than clay in improving the flame retardancy of the materials and promoting carbonization in the polystyrene matrix. Comparison of the results from the microscale combustion calorimeter and the cone calorimeter indicate that the rate of change of the peak heat release rate reduction in the microscale combustion calorimeter was slower than that in the cone. Both heat release capacity and reduction in the peak heat release rate in the microscale combustion calorimeter are important for screening the flame retardant materials; they show good correlations with the cone parameters, peak heat release rate and total heat released.     

Preparation and thermal properties of a novel flame retardant copolymer

A monomer, acryloxyethyl phenoxy phosphorodiethyl amidate (AEPPA), was synthesized and characterized using Fourier transform infrared (FTIR), ¹H nuclear magnetic resonance spectroscopy (¹H NMR) and ³¹P NMR. The copolymer with various amounts of styrene (St) was obtained by the free radical bulk polymerization between AEPPA and St, and characterized using ¹H NMR. The thermal properties of the copolymers were investigated with thermogravimetric analysis (TGA) in air and nitrogen atmosphere, and differential scanning calorimetry (DSC). The TGA results in air indicated the copolymers with AEPPA show higher thermal stability than those without AEPPA. However, the TGA results in nitrogen showed that the decomposition temperature decreased and the char residue increased with the increase of AEPPA. The glass transition temperature (T_g) of the copolymers from DSC indicated that a inverse proportion was observed between T_g and the amount of AEPPA incorporated. The flammability of the copolymers was evaluated by microscale combustion calorimeter (MCC). The MCC results showed that AEPPA can decrease the peak heat release rate (PHRR) and the heat release capacity (HRC), and the sample CP10 shows the lowest PHRR and HRC.     

Determination of antioxidants in polyolefins by pressurized liquid extraction prior to high performance liquid chromatography

The effect that a high amount of mineral filler might have on the extraction process of antioxidants from polyethylene and polypropylene was investigated. Extraction of Irganox 1010, Irganox 1076 and Irgafos 168, along with its oxidation product 2,4-di-tert-butylphenol, from freeze ground polyethylene–based (PE–based) and polypropylene–based (PP–based) mineral concentrates of 85 w/w calcium carbonate (CaCO₃) and 75 w/w talc was carried out by pressurized fluid extraction (PLE) prior to high performance liquid chromatography (HPLC). Results indicate that 85 w/w CaCO₃ did not affect the extraction process from PE or PP. For talc concentrates, additive recovery from PE and PP was considerably lower. The relation of recovery yield and mixing time was investigated for the talc concentrates and it was concluded that the presence of talc seemed to accelerate the rate of antioxidant consumption during sample processing, thus, less antioxidant was left to be extracted from the polyolefin; rather than talc has limited the extraction process. The method developed in this work has been applied to determine these compounds in several commercial samples.