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 users of ATH were polyacrylic acid vinegar, followed by unsaturated polyester—especially glass fiber-reinforced polyester. Additionally, polyolefins and PVC products also incorporated significant amounts of ATH.
As environmental concerns grew, the demand for halogen-free flame retardants increased, driving the market for alternatives like ATH. New evaluations of antimony trioxide, zinc borate, molybdenum compounds, and polyphosphoric acid have emerged, offering options that can be used alone or in combination with halogen-based materials. Many international companies are now focusing on developing various inorganic flame retardants to address issues such as smoke suppression, char formation, and thermal insulation.
For example, Novatoch, a new product developed by blending magnesium hydroxide from Versama and magnesium carbonate from Elastocarb with processing aids, effectively reduces fuming. Similarly, companies like Morton International Specialty Chemicals have introduced products that enhance flame retardancy in rigid PVC, thermoplastic elastomers, and fibers.
It is widely accepted that producing ultrafine particle powders is key to achieving optimal flame retardant performance. While Alfrazon’s Ulfracarb products have lower thermal stability compared to general-purpose flame retardants, they still outperform ATH. Adding just 0.5% magnesium hydroxide to plastic can significantly reduce smoke while maintaining high whiteness and mechanical properties.
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, potentially replacing fluoropolymers in pressurized cable jackets and brackets.
The US Borax Corporation reduced the average particle size of its zinc borate from 2–4 microns to less than 1 micron. This ultra-fine powder (0.5–3 μm) enhances fiber processing and dispersion. It can be combined with ATH to promote charring at high temperatures and is suitable for wire and cable sheathing when used with magnesium compounds. The company uses XPI-187 zinc borate in engineering plastics, offering good thermal stability for use in wire sheathing and aircraft interiors.
Due to its low usage, zinc borate can effectively suppress smoke when used alone in PVC. Reports indicate 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 excellent low-smoke performance, making it an attractive option for fire-safe applications.
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