North America remains the largest producer and consumer of flame retardants globally. In 1996, the region consumed approximately 30,900 tons of flame retardants annually. Among these, aluminum hydroxide (ATH) was the most widely used, with a total consumption of around 24,000 tons that year. The primary applications for ATH included polyacrylic acid vinegar, followed by unsaturated polyester, particularly glass fiber-reinforced polyester. Additionally, polyolefins and PVC products also relied heavily on ATH for flame resistance.
The demand for ATH is expected to grow due to increasing environmental regulations aimed at reducing the toxicity of halogen-based flame retardants. As a result, there is a growing interest in halogen-free alternatives. At the same time, new evaluations of antimony trioxide, zinc borate, molybdenum compounds, and polyphosphoric acid have emerged, offering potential as standalone or hybrid solutions with halogenated compounds.
Many international companies are now focusing on developing various inorganic flame retardants that can effectively reduce smoke generation, promote charring, and provide thermal insulation. For example, the Novatoch product developed by Versama and Elastocarb combines magnesium hydroxide with magnesium carbonate and processing aids to significantly suppress smoke emissions. This technology has been adopted by companies like Morton International Specialty Chemicals and is effective in rigid PVC, thermoplastic elastomers, and fibers.
It is widely recognized that producing ultrafine particle powders is crucial for achieving optimal flame retardant performance. Although Alfrazon’s Ulfracarb products exhibit lower thermal stability compared to standard flame retardants, they still perform better than ATH. Adding just 0.5% magnesium hydroxide to plastic can enhance its flame-retardant properties while maintaining high whiteness and mechanical strength.
Climax recently made progress by using AOM white powder in rigid PVC for large water pipes and window frames. The company is also accelerating R&D on key-zinc system compounds to improve PVC performance. These compounds can replace fluoropolymers in pressurized cable jackets and brackets.
In the U.S., Borax Corporation reduced the average particle size of its zinc borate from 2–4 μm to less than 1 μm. This ultra-fine particle size (0.5–3 μm) enhances fiber processing and dispersibility. When combined with ATH, it promotes charring at high temperatures and is suitable for wire and cable sheathing when used with magnesium compounds.
Borax uses XPI-187 zinc borate in engineering plastics, which offers excellent thermal stability and is ideal for wire and cable sheathing and aircraft interior trim. Due to its low usage rate, zinc borate alone can effectively suppress smoke in PVC. It has been reported that when zinc borate is combined with hydrated metals, a ceramic film forms at temperatures above 500°C, enabling the production of specialized heat-resistant insulating films.
The combination of zinc borate and aluminum hydroxide provides an effective low-smoke solution, making it a popular choice in various industrial applications.
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