Exactly your chemistry.
Superior flame retardancy means
enhanced protection
for people, property and the environment
Exolit-Flame Retardants
C o n t e n t s
Superior flame retardancy means
enhanced protection for people, 4|5 Better flame retardants for the future –
Requirements and challenges
8|9 Optimum benefits for everyone in the 2|3
process chain – economic, ecological
property and the environment and technical
10|11 An extensive range with a broad
application spectrum
14|15 Low-emission flame retardants –
future-focused, effective and
environmentally friendly
16|17 Jointly successful
18|19 Quality in production and service
Better flame retardants
Future-focused
for the future –
Requirements and
challenges
The performance profile required of modern flame retardants
has changed significantly in recent years. Alongside their
effectiveness in the event of a fire, environmental considera-
tions play an ever greater role in all phases of the product life Fire test in line with DIN 4102, Part 8
Exolit AP 422 / Mowilith DM 230
cycle – from production and processing through to actual use
and end-of-life recycling. It's an issue that has been initiated
by the end users of the products and followed up by the The increasing focus on the health and environmental com-
processors. As a global market leader in non-halogenated patibility of flame retardants has resulted in a steady decline
flame retardants, Clariant regards its offering of products that in the acceptance of halogen-containing products. Moreover,
provide the greatest technical, economic and ecological properties like smoke density and toxicity are becoming
benefits as being a responsibility. higher priorities.
At the same time, cost pressures in industry are rising:
cost-effective processing of flame retardants is essential
nowadays; additives have to be developed that can be
optimally integrated in the production process.
The growing use of plastics in areas that impose particular
flame retardancy requirements means that other properties
Exolit-enhanced products have been have to be included, whether commodity or engineering plastics
installed in the Arke stadium, Enschede.
are involved and whether they are destined for use in automotive
components or building materials. Europe-wide standards and
guidelines are likely to require even stricter benchmarks for
flame retardancy.
Clariant's Flame Retardants Business Line responded early to
this changing scenario and has been developing future-focused
products that offer optimum benefits – at all levels of the
process chain.
4|5
Dr. Hans M. Deger, Head of Flame Retardants Business Line, and
Dr. Rüdiger Walz, Head of Flame Retardants Marketing: "Short decision
paths, flat hierarchies and teamwork form the basis of our daily work."
The Exolit product family (known as Hostaflam until June 1998),
which is available worldwide, is the result of decades of
experience: Clariant is an international market leader in non-
halogenated flame retardants and has an ongoing development
program, so it can offer optimum flame retardant solutions for
a wide variety of materials and applications.
Plastics are used in countless
applications nowadays.
1 Processors and end customers are paying greater attention
to the environmental compatibility of products. A well-known,
international personal computer manufacturer has now
decided only to sell monitor housings that contain low-
emission flame retardants.
2 The public call for safe, environmentally friendly solutions in
fire protection is becoming more urgent. The discussion of the
dangers of halogen-containing flame retardants is intensifying.
3 Industry agrees with these demands and takes account of
them by imposing its own restrictions, among other measures.
Since 1989, leading European manufacturers have chosen not
to use brominated diphenyl ethers as flame retardants. As
from 1999, some of them will cease using brominated products.
4 The legislation and regulations on low-emission, environ-
mentally friendly flame retardants are becoming more
stringent, more comprehensive and more international. In
Europe, the harmonization of flame retardancy standards for
the building industry, and others, is under way.
Dr. Walz:
“Having the right flame retardants
helps gain precious minutes
for saving lives in a real emergency.”
Dr. Sebastian Hörold, Research & Development: "Many tailor-made products
are the result of close cooperation with our customers!"
Dr. Rüdiger Walz and Karlheinz Schenkel: "Early involvement in the develop-
ment of European fire tests ensures that practical requirements are met."
6|7
Light stability of PP-containing
Exolit AP 750/Hostavin N 20
Flame retardant developers gain valuable insights into im-
proving their products by examining the reaction of an object
during fire tests.
Optimum benefits for
Optimum everyone in the process chain –
economic, ecological
and technical
This means, for example:
Development/Design: Designers want to use inexpensive
materials with an optimum, clearly defined property profile and
the latest design processes. In order to change the properties
of the supporting materials only to a small extent, a minimum
filling degree and a matching of the flame retardant to the
plastic are factors of particular importance.
Many industrial companies nowadays take a wide variety of Material production: Exolit flame retardants can be worked
factors into account when choosing materials and additives. in well and are easily processed by compounders and others.
An all-encompassing approach to the choice of materials, The product form is adapted to the production process.
covering both the advantages and disadvantages, is taken
from the outset. Clariant's goal is to produce flame retardants Production: If plastics that contain flame retardants are easy
that offer benefits at every stage of the process chain – right to process, then production is inexpensive. Suppliers, e.g.
through to the recycling of the products. injection-molders, can optimally exploit the technical properties
of the materials.
Flame retardancy/application: The purpose of the flame
retardant – to be effective in a fire – must of course be fulfilled.
In addition, the virtual absence of emissions (e.g. in terms of
smoke density and fogging) offers significant advantages for
the human and natural environment. The use of high-quality
materials creates long-lasting products that help enhance the
image of the original equipment manufacturer (OEM) among
end users, for instance if the OEM employs non-halogenated
flame retardants with exceptionally high light stability.
Dr. Martin Sicken, Flame Retardants R&D: "Taking account of
demands in the processing chain demands close study of all
the processing steps."
Recycling: At the end of the product life cycle, plastics that
contain flame retardants can be readily recycled or disposed
of in an environmentally neutral way.
Close coordination with the production department ensures the
best cost-effectiveness for our flame retardants.
8|9
Dr. Wolfgang Schick, Plant Manager: "Modern process control
ensures constant quality of the Exolit grades."
Of course, not only the properties but also the cost analysis
is based on this comprehensive perspective: determining the
life-time costs creates transparency here. The flame retardant
with the lowest purchase price is by no means the most
economic!
This all-inclusive product assessment, which takes account of
the needs of all the sectors involved, is the focus of research &
development at Clariant. Customer requirements cannot be
met for all applications with just one product group. That's
why the Exolit range comprises several product families and
Die Eigenschaften unserer
numerous formulations tailored to customer demand or a Flammschutzmittel müssen auch
in späteren Verarbeitungsstufen
specific application. Materialeigenschaften erhalten
(Hier: Spiraltest mit Exolit AP 750).
An extensive range
Extensive with a broad
application spectrum
Exolit AP
The Exolit range consists mainly of three product groups, all of Ammonium polyphosphate – a polymer flame retardant ma-
which are based on the flame retardant effects of phosphorus terial – is the basis for this product family, which, as a result
compounds. The phosphorus compounds decompose during a of modification and synergist mixtures, covers a very broad
fire; this removes water from the supporting material and application spectrum.
causes charring. The carbon, which is additionally protected
against oxidation by a coating of polyphosphoric acid, isolates Exolit AP 422 and Exolit AP 462 are high-quality additives for
the still intact material from the flames. As this process takes intumescent coatings. Even at layer thicknesses of under 1mm
place only on the solid surface of the material, emissions are they achieve fire resistance times of over 30 minutes. Apart
minimized – a key property of flame retardants designed for from metal structures, application areas include cable and
the future. wood. Even textiles and papers can be given flame retardant
properties with intumescent coatings based on Exolit AP.
In the case of thermosets like epoxy resins and unsaturated
polyester resins, Exolit AP 422 paves the way for the production
of lightweight components with low solids content.
In polyurethane rigid foams that are used e.g. for insulation
purposes by the building industry, migration strength and low
smoke density play a special role. Here, Exolit AP 422 or Exolit
AP 452 (in dispersion form) provides a solution, since Exolit AP
422 does not impair the recyclability of PU foams.
Dr. Werner Krause, Head of Flame Retardants R&D: "Having
a research strategy that's in line with market trends is
important for the future success of our flame retardants."
Intumescent coatings are
becoming increasingly impor-
tant in fire protection for
buildings worldwide.
10|11
Flame-retardants are included in SMC com-
ponents used in the rail transportation sector.
Combined with synergists, ammonium polyphosphate becomes
highly effective in polyolefins (polypropylene and polyethylene).
Because of their effectiveness, Exolit products AP 750, AP 751
and AP 752 permit low dosages and lead to optimal mechanical
properties. They also facilitate the replacement of, for example,
electronic components made of flame-resistant ABS by less
expensive PP compounds (reinforced in some cases) and thus
reduce the range of materials.
The whole Exolit AP product family is characterized by extremely
low smoke density. Exolit AP is non-toxic and does not accumu-
late in the environment.
Different formulations
of Exolit AP.
Exolit RP
Red phosphorus is one of the most effective flame retardant
for plastics: it is used wherever the greatest possible flame
retardancy is required in combination with excellent material
properties.
Thanks to its very good electrical properties (e.g. low surface
conductivity and high tracking resistance) and high effectivity,
that permits low dosages, red phosphorus is an ideal flame
Dr. Norbert Weferling, R&D, Knapsack: "In the search for new solutions we are an
ideal partner because of our years of experience in developing non-halogenated retardant for electrical and electronic components. However,
flame retardants."
special retardation and stabilization through to microencap-
sulation are required – process steps that have been established
Exolit OP at Clariant for years.
The diversity of organophosphorus chemistry permits the pro- As the handling of pure red phosphorus requires particular
duction of optimally formulated flame retardants that do not know-how, Exolit RP products are offered as concentrates.
contain halogens. Consequently, flame retardant Exolit OP 550 This substance can then be used readily, e.g. in polyamide 6.6,
and others work into the polyurethane matrix like a polyol. It phenolic and epoxy resins, polyurethanes, dispersions and
shows no migration, is more effective than the usual additive latices.
flame retardants and has only a minimal impact on the material
properties, e.g. those of a PU soft foam.
The Exolit organophosphorus product family also forms the
starting point for future-focused, effective flame retardants for
thermoplastics like ABS, which are being increasingly used in
technically demanding applications.
Our flame retardants are the technically superior solution.
Phosphorus Red concentrates
in granule form offer safe
handling.
12|13
Dr. Friedrich Kolkmann, Plant Manager:
"Customers benefit from our know-how."
Flame retardants in trains and electrical components meet
increasingly tough requirements.
Low-emission flame retardants –
Low-emission future-focused, effective
and environmentally friendly
Apart from its density, the toxicity of the smoke is a key factor.
If a train is on fire, the essential thing is to stop its spreading
and to extinguish it rapidly so that as few people as possible
are harmed by the toxic gases emitted by the fire.
The smoke toxicity is considerably reduced by the use of non-
halogenated flame retardants, for when halogens like chlorine
and bromine react with other substances toxic fire residues
like dioxins may be formed.
Low smoke corrosivity is a factor that mainly serves to protect
Claudia Petzold, Flame Retardants Sales: "The product manager plant and equipment. Corrosive gases can have serious effects
is the expert contact for all order-related queries – he’s responsible
for production planning. In this way we ensure optimum, reliable in that, for instance, they cause permanent damage to commu-
delivery to our customers."
nication networks or power supply control systems. In any
case, safety-related components must be replaced after a fire.
Clariant's Exolit range is characterized by its very low level of Low smoke corrosivity is therefore another important criterion
emissions. Flame retardants belong in the material – it is a when selecting a flame retardant. Apart from being low-emission,
health care principle and a long-term quality criterion that the the flame retardant should also exhibit minimum migration.
additive concentration in the material remains constant. It thus
fulfills the technical demands of various industries.
Bromine- or chlorine-containing flame retardants give off
corrosive smoke in a fire – in concentrations that can cause
damage in addition to that resulting from the actual fire. In
addition, the increased smoke gas density leads to poor visibility,
making work difficult for the rescue teams and increasing the
risk of panic among those caught in the impenetrable smoke.
Public areas need products with flame retardants to
make them safer. Intumescent coatings are an ideal
way to combine attractive architecture with fire safety.
More and more customers insist on environmentally-friendly
and low-smoke flame retardants.
14|15
When the supporting material reaches the end of its service
life – and is thermally or mechanically recycled or transferred
to a landfill – the flame retardant must not give off any emissions
harmful to health or the environment. Ideally, it should retain
its flame retardant and mechanical properties even if it is
recycled several times.
The non-halogenated Exolit product group described here fulfills
the demands specified. Processors and users have a future-
focused, effective flame retardant program that can be
harmonized by synergists and special formulations to conform
to individual application conditions.
Achim Hennemann, Flame Retardants Marketing:
"Flame retardants play a major role when selecting material
for interior furnishings."
Success Jointly successful
Karlheinz Schenkel: "The fire test
building is an important tool in
developing flame retardants that
From dialogue to product meet tomorrow's needs."
At the start of a successful cooperation between a flame retardant
user and Clariant there is generally an intensive dialogue: the
requirements profile of the desired flame retardant effect is
jointly determined. Drawing on its decades of know-how and
experience in the sector, Clariant's Application Technology
recommends a product from the Exolit family – or else develops
a special formulation.
The fire test building
It was built in 1978 and since then has been regularly modernized
to keep pace with technical developments. Over an area of
1,800 m3, fire tests up to real-life mock-ups are documented
Achim Hennemann und Heinz Peter Zopes, in photos and video recordings. A wide range of test beds and
Flame Retardands Marketing:
"Customer-specific developments are part of facilities allow the certification of products in line with German,
our daily work."
European and US standards. The fire test building has been
approved by the Federal Railways Office (EBA) and the Federal
To relieve users of costly and labor-intensive research and Aviation Office (LBA) in Germany and is authorized to issue the
development work, model formulations are first of all produced relevant certificates.
which are extensively tested in the laboratory and pilot plant.
Conventional processing methods are used here, like injection-
molding, extruding, foaming, compression molding and coating.
The scale-up can be precisely calculated.
The chemical pilot plant produces special developments on a
semi-commercial scale that the user can take for test purposes.
Comprehensive advice on processing the flame retardant is
also part of Clariant's service. Effectiveness and application
tests can be conducted at the Competence Center laboratories
in Knapsack and Gersthofen as well as at the fire test building
in the Höchst industrial park.
Dr. Christian Eilbracht, Flame Retardants R&D: "By building teams with
other departments, we can rapidly provide problem-solving products for
customers."
16|17
The industry teams
To offer its customers optimum service at all times, the Flame
Retardants Business Line has created teams, each of which
focuses on a particular customer industry. Employees from
research, application technology, sales and marketing come
together here and "bundle" the know-how that exists in the
company. This process helps identify the demands of all those
involved in the production chain – from the raw material producer
and compounder, processor and component manufacturer
through to the end user and consumer – and helps the teams
respond to those demands.
Exolit flame retardants are charac-
terized by their low smoke density.
Direct links between the departments and their proximity to (Here Exolit AP 422 in PU foam
compared with conventional flame
customer tasks and problems ensure rapid, unbureaucratic retardants).
service – a factor that becomes increasingly important with
the use of future-focused flame retardants.
Quality Quality in production and service
The international presence of Clariant AG ensures the availability
of Exolit flame retardants as well as expert application advice
The certification of the production facilities to DIN EN ISO in over 80 countries.
9001 documents and confirms the consistently high quality
levels, the large degree of vertical integration and the years Flame retardants – for today and tomorrow
of know-how in handling and processing raw materials. Clariant's Flame Retardants Business Line is the global leader
Modern company-wide data processing and communication in future-focused, low-emission flame retardants.
systems facilitate short decision paths when questions arise;
a well established logistics chain has made on-time delivery This leadership position obliges us to develop and refine our
its top priority. product range so that as many users as possible in a wide
variety of sectors can include eco-friendly, non-toxic and eco-
nomic flame retardants in their raw materials and products.
Recent scientific findings are flowing into Clariant's research
& development activities. Global regulations as well as industry-
specific specifications are also being met. This approach
ensures that future generations of the Exolit family can right-
fully be called "future-focused".
One very important aspect of the continuous, market-responsive
development of our product portfolio is to have an exchange of
opinions and experience with flame retardant users. We sin-
cerely invite them to let us know their problems and wishes –
Dr. Rudolf Staab,
Head of the Additives and we promise to listen carefully and provide sound advice.
Business Unit: "Customers
and their needs are our
top priority."
And we should always respect
the world around us.
Helga Becker and Jürgen Clasen, Analysis and Quality Assurance:
"Tackling new challenges is part and parcel of our daily work."
18|19
The safety of people and their environment is our primary concern.
Please note
This information is based on our present state of knowledge and is intended to
provide general notes on our products and their uses.
It should not therefore be construed as guaranteeing specific properties of the
products described or their suitability for a particular application.
Any existing industrial property rights must be observed. The quality of our products
is guaranteed under our General Conditions of Sale.
Edition: March 2000
Clariant GmbH
Pigments & Additives Division
Flame Retardants Marketing
65840 Sulzbach
Germany
Telephone: +49/6196/757-8112
Telefax: +49/6196/757-8977
Internet: www.clariant.com
