New Product Development in Flame Retardants for the Polyurethane Industry

Mike NagridgeManny PinzoniAndrew PiotrowskiJeffrey StowellBarbara Williams

ICL-IP America Inc.Ardsley Park430 Saw Mill River RoadArdsley, NY 10502USA

Presentation Outline

• Who is ICL-IP

• Introduction & Current Market Trends

• New Product Developments From ICL-IP

• Future Activities

ICL-IP: Company Profile

Israel Chemical Limited (ICL) is a multinational chemical company

ICL-IP is the Industrial Products Group within ICL

One of the world’s largest developers, manufacturers and suppliers of flame retardants

Diversified customer base around the globe

Strong emphasis on innovation

Maintains commitment to the highest standard of customer service

ICL-IP R&D

Strong dedication to R&D and Technical Service

Key areas of expertiseProduct Development

Polyurethane applicationsThermoplastic resin applicationsTextile applicationsAll areas of flame retardant needs

Technical Market SupportProcess Research

Br, P, Mg & Nitrogen FR’s = no “chemistry bias”

Introduction

• Flame retardants play an important role in safeguarding life and property

• Flame retardants have been used to meet fire safety requirements mandated by numerous regulations (e.g.)– For flexible foam

• Cal TB 117, MVSS-302, BS5852

Introduction

• New sustainable flame retardants must meet a broad array of criteria

– Flammability performance– Foam physical properties– Health– Safety– Environment– Customer processing– Cost performance

Market Trends

• IKEA Requirements

• CertiPUR Requirements

• Automotive

• New Product Direction

Market Trends• IKEA

– Furniture foam applications

– Updated specification (IOS-MAT-0010, version 9)• effective Oct 9, 2009

– Compliance within 4 months except TDCP (Nov 1, 2010)• Several products added to the banned list; some worth mentioning

– TEPA, TDCP, TCEP, TPP

– ICL-IP worked with IKEA to bring science based testing to the standard

• Ongoing dialogue• Technical support data

– Fraunhofer Testing• TCPP not included in new specification

Market Trends

• CertiPUR Certification– From a flame retardant supplier perspective,

provides a method of testing to determine acceptable products

– ICL-IP supports CertiPUR certification• Technical assistance• Monetary support

Market Trends

• Automotive– Increasing concerns regarding VOC / FOG– Manufacturer standards vary

• Daimler – most stringent specification• Audi / VW – stringent requirements• Then most others

– Recent discussion of TDCP use in Europe & US• Minimal interest in alternatives at this time

Market Trends

• There is a growing awareness regarding the presence of VOC’s in flexible polyurethane foam

• IKEA has taken a step forward to limit VOC’s in their products; a move that will no doubt impact furniture as well as other end use markets

• Halogen Free– Additive, Reactive and Polymeric

• Reactive / Polymeric FR product solutions– Reactive Halogen and/or Phosphorus solutions– Polymeric Halogen and/or Phosphorus solutions

New Product Developments From ICL-IP

• Work presented today is focused on Halogen-Free solutions that pass the new IKEA standard– Four new developmental products are presented

• E08-16T – low scorch hal-free FR (not TSCA listed)• E10-55 – moderate scorch hal-free FR (not TSCA listed)• E10-54 – moderate scorch hal-free FR (TSCA listed)• E10-59 – moderate scorch hal-free FR (TSCA listed)

Flexible Foam Flame Retardant Development

• Foams with like densities, air flows, and overall foam quality are produced and tested

• Results are compared to known commercial flame retardants – Fyrol FR-2 (TDCP), Fyrol HF-4 & Fyrol PNX– Flammability – loading levels (FR efficiency)– Discoloration – scorch potential– Foam physical properties

Lab Hand-mix Polyurethane Formulations

Density (pcf) 1.0 1.5 1.8

Voranol polyether polyol (3000 mw) (Dow) 100.00

variable

5.60

0.25

1.00

0.35

110

100.00

Flame retardant

100.00

variable

3.85

0.23

0.80

0.45

variable

H2O 3.55

Catalyst, Dabco BLV (Air Products) 0.23

Silicone surfactant L-620 (GE) 0.80

Stannous octoate T-10 (Air Products) 0.40

TDI Index 110 110

Furniture Foam ApplicationsCal TB117 Test – 1.0 pcf

0

5

10

15

20

Pass

ing

Leve

l (ph

p)

Fyrol FR-2 Fyrol HF-4 Fyrol PNX E08-16T E10-55 E10-54 E10-59

Furniture Foam ApplicationsCal TB117 Test – 1.5 pcf

0

5

10

15

20

Pass

ing

Leve

l (ph

p)

Fyrol FR-2 Fyrol HF-4 Fyrol PNX E08-16T E10-55 E10-54 E10-59

Furniture Foam ApplicationsCal TB117 Test – 1.8 pcf

0

5

10

15

20

Pass

ing

Leve

l (ph

p)

Fyrol FR-2 Fyrol HF-4 Fyrol PNX E08-16T E10-55 E10-54 E10-59

Automotive Foam ApplicationsMVSS-302 Test – 1.5 pcf (SENBR)

* Passing with SE rating

0

5

10

15

20

Pass

ing

Leve

l (ph

p)

Fyrol FR-2 Fyrol HF-4 Fyrol PNX E08-16T E10-55 * E10-54 * E10-59 *

Automotive Foam ApplicationsMVSS-302 Test – 1.8 pcf (SENBR)

* Passing with SE rating

0

5

10

15

20

Pass

ing

Leve

l (ph

p)

Fyrol FR-2 Fyrol HF-4 Fyrol PNX E08-16T E10-55 * E10-54 * E10-59 *

Flexible Foam Discoloration

• Oven Scorch Method– Recently developed by ICL-Industrial Products– Evaluates the impact of flame retardants and anti-

scorch packages on scorch propensity in foams– Increasing time on the graphs represent

increasingly severe foaming conditions• High water formulations• Longer cooling times• Higher ambient temperatures and humidity

Scorch Performance

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

50.00 70.00 90.00 110.00 130.00 150.00

Time (min)

Del

ta E

Fyrol PNXFyrol FR-2E10-59E10-55E10-54Fyrol HF-4E08-16T

Summary / Conclusions

• E08-16T– Very low scorch potential– Similar in efficiency to TDCP– Product not yet registered– Commercial availability expected mid 2011

• E10-55– FR & scorch properties similar to TDCP– Commercial availability expected mid 2011

Summary / Conclusions

• E10-54 & E10-59– FR & scorch properties similar to TDCP– TSCA registered– Available for lab and commercial evaluations

• Fyrol HF-4 and Fyrol PNX– Commercially available halogen-free products

• SaFRon 7700– Commercially available reactive bromine/phosphorus

product

Future Activities

• ICL-IP will continue to defend the use of safe and effective FR products

• Our work will continue to be guided by public perception and demand for low VOC products, with particular focus on halogen-free, reactive and/or polymeric flame retardant products

• Future efforts are focused on commercialization of the products presented earlier and continuing the synthetic and process development activities required to bring the next generation of low VOC FR products to the flexible foam market

Thank you for your kind attention