Project's information
Project's title | Study on the synthesis of environmentally friendly fire-retardant nanocomposites based on thermoplastic, thermoset, and rubber matrices for the manufacturing of fire-resistant products |
Project’s code | TĐPCCC.00/21-23 |
Research hosting institution | Institute of Chemistry |
Project leader’s name | Prof. Nguyen Van Tuyen |
Project duration | 01/01/2021 - 31/12/2023 |
Project’s budget | 43,200 million VND |
Classify | Grade A |
Goal and objectives of the project | General objectives |
Main results | Theoretical results: + The project has successfully synthesized flame-retardant substances such as TiO2, Mg(OH)2, bentonite, APP, and nano-silica. These materials are cost-effective, with simple production methods that can be scaled up to pilot production. + The project has systematically studied SAP materials derived from natural sources such as cellulose, alginate, and starch and has developed specific formulations for gels formed from these SAPs as follows: + SAPNB has been synthesized by graft polymerization of acrylic acid and the crosslinker N, N'-methylene-bisacrylamide (MBA) combined with nano silica, nano bentonite, and nano Mg(OH)2. This material produces a gel formulation with excellent adhesion to material surfaces, impeding combustion. The SAPHP01 additive, with 30% SAPNB content, possesses a high hydrophilic-lipophilic balance (HLB=10), allowing rapid water absorption to form gel01 (comprising 5% SAPHP01 and 95% water), which is used as a material to prevent and extinguish fires. Experimental results indicate that gel01 can effectively extinguish Class I fires in under 300s , with fire resistance ranging from 1000 to 1300°C for 40s when applied in a 2 mm layer. + The TS-AA-AMPS/APP material was synthesized from modified starch, AA, and AMPS, incorporating 3% APP by weight. The SAPHP02 additive, used to formulate gel02 containing 32% TS-AA-AMPS/APP, has an HLB value of 4.3, offering excellent water absorption and retention. Gel02, prepared from 3.5% SAPHP02 and 96.5% water, demonstrates exceptional adhesion to wooden surfaces (99%). Testing of the gel02 system shows a Class I fire extinguishment time of less than 300 seconds (262 seconds) and fire resistance of up to 45 seconds with a 2 mm gel coating. + Successful in determining the method of processing natural cellulose fibers to enhance the flame resistance properties of cotton fibers with some flame retardant additives, including: the commercial additive Pyrovatex CP, extracts from some agricultural by-products (jackfruit peel, dragon fruit peel, watermelon peel), and nano-sized inorganic particles (nanoclay, nano silica particles, nano zinc oxide). + Successful in determining some important properties of flame resistance cotton fibers treated with flame retardant additives. + Successful in determining the method of processing the treated cotton fibers into flame resistance textiles, as well as the method of applying these flame resistance textiles in the manufacturing of practical products such as flame resistance clothing. + Successful in determining some toxic gaseous products formed from the combustion process of cotton textiles, as well as cotton textiles treated with the investigated flame retardant additives. + Synthesized 24 organic compounds containing DOPO. DOPO and compound FR3 were found as potential flame retardant additives. + Synthesized 3 organic compounds containing spiro phosphorus heterocycle used to modify flame retardant nanocomposite material. + Fabricated and researched the characteristics of nanohybrid materials based on carbon nanotubes modified with organic compounds containing DOPO or spiro heterocyclic compounds. The results revealed that DOPO-modified thermally expandable graphite EG@DOPO with 10,4 wt% DOPO and a particle size of 100 mesh is found to be suitable as a fireproof additive. + Fabricated and researched the characteristics of inorganic/organic hybrid materials based on halloysite (HNTs) or montmorillonite (MMT) modified with organic compounds containing DOPO or spiro heterocyclic compounds. Nanoclay oMMT2 which contained about 12.3 wt% of the ammonium salt and 29.8 wt% of DOPO, possessed an interlayer spacing of 31.5 Å, and a structure and thermal properties suitable as a flame retardant additive. + Researched and developed a flame retardant combination for nanocomposite materials based on acrylonitrile butadien styrene (ABS) including aluminum trihydroxide/red phosphorus (ATH-RP)mgst (7.5 wt%), EG@DOPO (3,75 wt%) and potassium perfluorobutane sulfonate (3.75 wt%). + Researched and developed a flame retardant combination for nanocomposite materials based on PC/ABS (80/20 wt%) using a mixture of 1.0 wt% of GNP and 0.5 wt% of PFBS additives. The combination of GNP and PFBS resulted in improved dispersibility of the additives within the PC/ABS blend, delivering good flame-retardancy properties and substantial enhancement in mechanical properties, such as impact strength, tensile strength, and flexural strength, compared to the neat PC/ABS blend. + Researched and developed a flame retardant combination for nanocomposite materials based on polyethylene (PE) including nanoclay oMMT2 (3 wt%), (ATH-RP)mgst (14 wt%) and EG@DOPO (1 wt%). + Fabricated zinc borate nanocomposites and evaluated the fire resistance of zinc borate/red phosphorus/expanded graphite nanocomposite based on HDPE resin. The fire resistance of nZB/P/EG/HDPE4 composite (mass ratio 6/10/6/78) achieved the UL-94 V-0 rating and the LOI value of 26.8%. + Researched and developed a flame retardant combination for epoxy-based nanocomposite materials including APP-PEI mixture (5 wt%) and derivatives containing DOPO (5 wt%). Nanocomposite EP/5APP-PEI/5FE15 exhibited high fire resistance V-0, LOI value of 28.6% and exhibited relatively high mechanical performance with an impact strength of 26- 28 kJ/m2. + Fabricated 50 pieces of 24FO fiber optic splice closures from flame-retardant ABS-based nanocomposite. + Fabricated 120 pieces of 24FO fiber optic splice closures from flame-retardant PC/ABS-based nanocomposite. Dimensions (Length x width x height): 410 x 170 x 80 mm. The fire resistance of the fiber optic splice closure achieves UL-94 V-0 and the LOI value of 27.2%. Impact resistance to resist the impact force of a 1 kg round steel ball from a height of 2 m at room temperature, tested according to IEC 61300-2-12 Method B; Compression resistance of 1000 N/25cm2 for 1 hour, tested according to IEC 61300-2-10 standard; Operating temperature range: -10 oC ̶ 65 oC (±2 oC), tested according to IEC 61300-2-22 standard (IEC 60068-2-14 Test Nb). + Fabricated 240 pieces of electrical insulation board from flame-retardant PE-based nanocomposite. The fire resistance of the electrical insulation board achieves the UL-94 V-0 and the LOI value of 27.6%. The mechanical properties of the electrical insulation board meet the requirements of TCVN 9569:2013: un-notched impact strength value is 11.9 kJ/m2, modulus of elasticity in tension is 319 Mpa. + Successful Synthesis of Nano Aluminum Hydroxide via Hydrothermal Method: Nano aluminum hydroxide particles with uniform sizes ranging from 150-200 nm were successfully synthesized using the hydrothermal method at a temperature of 120°C in the presence of surfactants. Factors affecting the morphology of nATH particles, including precursors, hydrothermal time, and surfactants, were investigated. The survey results indicate that aluminum salts have a negligible effect on particle morphology; 12 hours is the optimal hydrothermal time to achieve uniformly sized particles, and CTAB is the most suitable surfactant for producing uniformly shaped nATH particles. + Successful Synthesis of Flake-Like Nano Zinc Borate: Flake-like nano zinc borate with the formula 2ZnO.3B2O3.3.5H2O and an average particle size of about 100 nm was successfully synthesized using the co-precipitation method. Factors influencing the structure and morphology of the nano particles were examined. Results indicate that zinc sulfate is an appropriate precursor, the reaction temperature of 80°C, and polysorbate 80 is a suitable surfactant for synthesizing thin, uniformly shaped zinc borate nano sheets with high purity. + Expandable Graphites (EG) with Various Particle Sizes were Successfully Synthesized via a Chemically Oxidative Intercalation Method: The effect of graphite particle size on the expanded volume of EG was investigated. The results indicated that EG with large particle sizes had a lower initial expansion temperature and a much higher expaned volume than those with small particle sizes. Notably, EG with a particle size of +100 mesh exhibited the largest expanded volume of 225 mL/g. + Successful Synthesis of Nano Cu2O Using Reduction in Solution: Nano Cu2O material was successfully synthesized using the reduction method in solution with CuSO4.5H2O as the precursor and NaBH4 as the reducing agent in an alkaline environment. The synthesized Cu2O nanoparticles are spherical, pure, with an average size of 100-150 nm, absorbing wavelengths around 535 nm and having a specific surface area of 6 m²/g. + Successful Synthesis of Nano-Al2O3 Using Sol-Gel and Ultrasonic Methods: Using the sol-gel method combined with ultrasonication, nano Al2O3 material was successfully synthesized. The synthesized material has a small and uniform size ranging from 10-15 nm and a high specific surface area of up to 179 m²/g in the γ-Al2O3 state, which is widely used in practice today. + Inorganic Flame Retardants was conducted using various modifying agents such as silane compounds and stearate salts. Results show that magnesium stearate is suitable for modifying aluminum hydroxide, calcium stearate for modifying magnesium hydroxide and zinc borate, and silicon oil for modifying red phosphorus. A 3% modifying agent is the appropriate amount for modifying inorganic additives for flame-retardant composite fabrication. + Successful Modification of Commercial Ammonium Polyphosphate (APP) Flame Retardant: The commercial flame retardant ammonium polyphosphate (APP) was successfully modified with various agents including silane agents like KH-550, vinyltrimethoxysilane (VTMS), melamine-formaldehyde (MF), MF + phytic acid, urea-melamine-formaldehyde (UMF), and glycidyl methacrylate (GMA). These polymers encapsulate APP particles, creating core-shell structures that enhance the dispersion of APP in polymer matrices. + Successful Development of High Flame-Retardant PP Composite: A high flame-retardant polypropylene (PP) composite with good mechanical properties was successfully developed. The flame-retardant properties of composites containing ATHmgst, MHcast, RPsi, MCPMHS, ZBcast, EG100, and their combinations were investigated to study the synergistic flame-retardant effects. Results show that a composite containing 18% of the nMH:MHcast:RPsi:EG100 combination in a mass ratio of 2:5.2:4.8:6 has high flame-retardant properties, good mechanical properties, and is made from environmentally friendly and low-cost additives. Therefore, this composite formula was selected for trial production of flame-retardant thermoplastic sheets. + Successful Application of Modified APP in Flame-Retardant PP Systems: Research on using flame retardant additives for PP based on modified APP showed that systems using APP encapsulated with agents such as VTMS (monomer) or MF, UMF (both as monomers and foaming agents) create effective polymer shells for optimal dispersion of APP in the PP matrix. Combining modified APP with carbonizing agents like PER and DPER results in high flame-retardant PP materials. Some successfully applied formulas in PP meeting registered criteria include: PP/MF-APP/PER/3/1: 70/22.5/7.5% PP/UMF-APP/DPER/3/1: 70/22.5/7.5% PP/VTMS-APP/DPER/3/1: 70/22.5/7.5% + Inadequate Flame-Retardant Properties in PMMA-Based Composites: Research on creating flame-retardant composites based on PMMA using APP combined with other flame-retardant agents showed that, overall, the flame-retardant properties did not meet requirements, although the mechanical properties met the registered criteria. + Successful Development of Flame-Retardant Nanocomposites Based on PUR Foam: Flame-retardant nanocomposites based on PUR foam were successfully developed using the free expansion method at temperatures of 20-25°C with different particle sizes of EG, MH, RP, APP, PER, nZB, nATH, and their combinations. The study of flame-retardant properties and mechanical properties showed that a nanocomposite containing the combination of nATH, APP, PER with a mass ratio of nATH:APP:PER = 2:12.86:5.14 has good flame-retardant efficiency, high compressive strength, and thermal insulation. Therefore, this nanocomposite formula was chosen for developing the trial production process of flame-retardant thermal insulation sheets. + Successful Development of High Flame-Retardant Epoxy Composites Using Modified APP: Flame retardants based on APP modified with agents like polyethylenimine (PEI) and GMA, combined with thermosetting epoxy resin, created composites with very high flame-retardant properties (LOI > 30%). The epoxy resin-based composites using 5-10% APP@GMA showed an LOI increase to 28% (using 5% APP@GMA) and up to 33% (using 10% APP@GMA). The APP@PEI additive, at an 18% level combined with a small amount of Cu2O (2%), increased the LOI of the composite to 32.5%. + Everal flame-retardant additive systems were developed for EPDM rubber, with APP@PEI-ATH (20:160 phr) emerging as the optimal system, achieving UL-94 V-0, an LOI of 31.6%, and superior mechanical properties. This system was selected for trial production of 20 m² of flame-retardant rubber. While the APP-PER-EG system (28.1:9.4:12.5%) combined with 12% PP met the required standards (UL-94 V-0, LOI 27.2%, tensile strength 11.74 MPa, elongation at break 667%, Shore A hardness 80.43), it was less effective than APP@PEI-ATH. The combination of APP@PEI with Mg(OH)₂ did not deliver the desired flame-retardant performance. + Improved Flame-Retardant Properties of NBR Rubber Composites: Studies on NBR rubber using flame retardant additives such as RP-Al(OH)3, EG-Al(OH)3, and APP-Al(OH)3 showed significant improvements in the flame-retardant properties of NBR rubber composites, meeting registered criteria. However, the mechanical properties of the resulting rubber composites did not meet requirements due to the inherently lower mechanical properties of NBR rubber compared to the registered criteria. + A process for manufacturing flame-retardant ABS-based nanocomposite materials based MB40FRABS has been developed at a scale of 50 kg/batch with ingredients including ABS (69.72 wt%), (ATH-RP)mgst (15.14 wt). wt%), EG@DOPO (7.57 wt%), and PFBS (7.57 wt%). + A process for manufacturing flame-retardant PE-based nanocomposite materials MB40FRHDPE has been developed at a scale of 50 kg/batch with ingredients HDPE (56,6 wt%), oMMT2 (6 wt%), (ATH-RP)mgst (30 wt%). + Successful Development of Technology for Flame-Retardant Thermoplastic Sheets: A successful technology for producing flame-retardant thermoplastic sheets based on PP with a formula of 2% nMH, 5.2% MHcast, 4.8% RPsi, 6% EG100, and 82% PP was developed. The technology was applied to the trial production of flame-retardant thermoplastic sheets, and the products met the registered criteria. + Successful Development of Technology for Flame-Retardant Thermal Insulation Sheets: A successful technology for producing flame-retardant thermal insulation sheets based on PUR foam containing a combination of 2% nATH, 12.86% APP, and 5.14% PER was developed. This technology was applied to the trial production of 30 m² of three-wave flame-retardant roofing sheets based on PUR with thicknesses of 50/92 mm. The product met the registered criteria as stated in the project proposal. + A procedure has been developed to analyze 5 new brominated flame retardants (NBFRs) (HCDBCO, BTBPE, TBPH, DBBPE, TBBPA-DBPE) in indoor dust samples on GC-MS equipment with good recovery of 97.5 - 100.5 %, limit of detection (LOD) of the method of 05 NBFRs in the range of 0.22 – 0.72 ng/g, limit of quantification (LOQ) of method of 05 NBFRs in the range 0.73 – 2.4 ng/g. + A procedure has been developed to analyze 14 phosphorus flame retardants (OPFRs) (TnBP, TCEP, TCIPP (1,2,3), DBPP, TDCIPP, TPhP, TBOEP, EHDPP, TEHP, TOCP, TMCP, TPCP) in indoor dust samples on GC-MS equipment with a good recovery of 80.8 - 103%, limit of detection (LOD) of the method of 14 OPFRs in the range of 0.76 – 3.12 ng/g, limit of quantification (LOQ) of method of 14 OPFRs in the range 2.53 – 10.4 ng/g. + A procedure has been developed to analyze 05 new brominated flame retardants (NBFRs) (HCDBCO, BTBPE, TBPH, DBBPE, TBBPA-DBPE) in water on a GC/MS instrument with good recoveries of 80.5 – 120.1 %, limit of detection (LOD) of the method of 05 NBFRs in the range of 6 – 14 ng/mL, limit of quantification (LOQ) of method of 05 NBFRs in the range 20 – 45 ng/L. + A procedure has been developed to analyze 06 phosphorus flame retardants (OPFRs) (TnBP, TCEP, TCPP, TDCPP, TPP, TBEP) in water samples on GC/MS equipment with good recovery of 98 - 100.5 %, limit of detection (LOD) of the method of 06 OPFRs in the range of 0.51 – 0.62 ng/mL, limit of quantification (LOQ) of method of 1.67 – 2.56 ng/L. + A procedure has been developed to analyze 06 phosphorus flame retardants (OPFRs) (TnBP, TCEP, TCPP, TDCPP, TPP, TBEP) in upholstered furniture foam samples on a GC/MS instrument with a good recovery of 97, 5 - 100.5 %, limit of detection (LOD) of the method of 6 OPFRs in the range of 1.01 - 1.39 ng/g, limit of quantification (LOQ) of method of 6 OPFRs in the range of 3.8 – 4.63 ng/g. + A procedure has been developed to analyze 06 phosphorus flame retardants (OPFRs) (TnBP, TCEP, TCPP, TDCPP, TPP, TBEP) in fabric samples of upholstered furniture on a GC/MS instrument with a good recovery of 97.5 – 100.6 %, limit of detection (LOD) of the method of 6 OPFRs in the range of 0.88 – 1.01 ng/g, limit of quantification (LOQ) of method of of 6 OPFRs in the range of 2.93 – 3.36 ng/g. + The project developed and issued a technical specification (TCCS) for VH-GEL01 for fire prevention and suppression, serving as a foundation for establishing a national standard (TCVN) and enabling future research comparisons. Applied results: + New products have been developed with effective fire extinguishing capabilities that meet Vietnamese standards and are of comparable quality to international products, eliminating the need for imports and ensuring human and social safety. The resulting products are more cost-effective than imports and can be researched and produced domestically. + The products are technically optimized, competitively priced (approximately 150,000 VND/liter), safe to produce, easily scalable, and completely non-toxic. They represent an economical and environmentally friendly solution with the potential to compete with international brands. + The products are the results of research aimed at practical applications such as fire-resistant insulation sheets; multipurpose rubber sheets used for machine lining, intricate machine parts such as gaskets, trunk liners, car floor mats, and all products requiring fire resistance based on EPDM rubber; fire-resistant plastic partition panels and all fire-resistant products based on PP plastic. + Successful in development of 03 technical processes for manufacturing flame resistance cellulose fibers and textiles, along with 01 technical standard for the manufactured flame resistance cellulose fibers and textiles, creating a solid foundation for applying the research results of this Project into production practice. + A process for manufacturing flame-retardant ABS-based nanocomposite materials based MB40FRABS has been developed at a scale of 50 kg/batch. + A process for manufacturing flame-retardant PE-based nanocomposite materials MB40FRHDPE has been developed at a scale of 50 kg/batch. + A technological process for manufacturing 24FO fiber optic splice closures from flame-retardant ABS-based nanocomposite has been developed. + A technological process for manufacturing electrical insulation boards from flame- retardant PE-based nanocomposite has been developed. + The analytical procedures have been applied to analyze Hanoi's indoor dust and surface water samples (rivers and lakes). And also analyzed the flame retardants in foam, furniture upholstery, and curtain fabric collected from the market, and analyzed the metabolites of flame retardants in the urine of people in Hanoi. + A set of data has been obtained on 06 organophosphorus flame retardants in surface water in 17 lakes and 06 rivers in the Hanoi area. + The risk of flame retardants in surface water to the ecosystem in rivers and lakes in Hanoi has been assessed. + A set of data on 14 organophosphorus flame retardants in indoor dust in the Hanoi urban area has been obtained. + The correlation between the content of flame retardants in indoor air and accumulation in the body of Vietnamese people has been evaluated. + The exposure level and human health risks of flame retardants in indoor dust were assessed. + Collected and analyzed metabolites of flame retardants in 61 urine samples collected from people in Hanoi, and estimated the exposure dose of people to flame retardants. + Collected and analyzed flame retardants in 31 samples of upholstery fabric and 40 samples of curtain fabric collected at the market. The dermal exposure risk of these flame retardants to human health has been assessed.
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Novelty and actuality and scientific meaningfulness of the results | + Researched and developed core formulations to create two new-generation, environmentally friendly fire prevention/extinguishing gel systems to meet the needs of firefighting forces, households, agencies, and businesses. |
Products of the project | Scientific papers in referred journals: |
Recommendations | After the implementation of the project, we would like to propose the following recommendations: |
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