FLAMERETARDANT ADDITIVES

Transcription

1 Report No. 92 FLAMERETARDANT ADDITIVES by HAROLD W. SCHEELINE Contribution by Norman Fishman January A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I I MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION SUMMARY General Aspects... Chlorinated Paraffins.. Derivatives of Hexachlorocyclopentadiene. Phosphate Esters... Economics Chlorinated Paraffins..... Hexachlorocyclopentadiene and Derivatives Phosphate Esters... Technical Aspects... Chlorinated Paraffins.. Hexachlorocyclopentadiene (HEX)... Hexachlorocyclopentadiene Adducts... Phosphate Esters... 3 GENERAL BACKGROUND ON FLAME RETARDANT ADDITIVES... Introduction Mechanisms of Fire Retardance... Test Methods Flame Retardants... Flame Retardant Systems.. References INDUSTRY STATUS Overall Industry Statistics 40 Antimony Oxide Chlorinated Paraffins Hexachlorocyclopentadiene Derivatives Phosphate Esters CHLORINATED PARAFFINS... Chemistry. Review of Processes... Process Description... Process Discussion... 'Cost Estimates... Capital Costs... Production Costs vii

3 CONTENTS 6 DERIVATIVES OF HEXACHLOROCYCLOPENTADIENE.. 83 Production of HEX Chemistry 83 Review of Processes HEX Production from n-pentane Process Description. 94 Process Discussion Cost Estimates HEX Production from Dicyclopentadiene. 109 Process Description. 109 Process Discussion Cost Estimates Production of HEX Adducts. 124 Chemistry 124 HEX Dimer Adduct of HEX and 1,5-Cyclooctadiene Adduct of REX and Furan 126 Adduct of HEX and Tetrabrominated Styrene Review of Processes Process Description Process Discussion Cost Estimates Capital Costs Production Costs TRIARYL PHOSPHATE ESTERS Review of Chemistry and Process Background. 149 Process Description and Discussion Cost Estimates ALKYL DIARYL AND HALOGENATED TRIALKYL PHOSPHATES Chemistry Alkyl Diary1 Phosphates Tris(8-chloroalkyl) Phosphate Tris(dichloropropy1) Phosphate Tris(2,3-dibromopropyl) Phosphate Review of Processes Alkyl Diary1 Phosphates Tris(chlorinated alkyl) Phosphates Tris(2,3-dibromopropyl) Phosphate Process Description viii

4 CONTENTS 8 (Continued) Process Discussion Cost Estimates Capital Costs Production Costs APPENDIX A DESIGN AND COST BASIS APPENDIX B PHYSICAL PROPERTIES OF SOME COMMERCIAL FLAME RETARDANT ADDITIVE PRODUCTS APPENDIX C PRODUCT TOXICITY AND HANDLING , CITED REFERENCES PATENT REFERENCES BY COMPANY ix

5 ILLUSTRATIONS 5.1 Chlorinated Paraffins: 70 Weight Percent Chlorine Chlorinated Paraffins Effect of Operating Level and Plant Capacity on Production Cost HEX Manufacture from n-pentane Effect of Operating Level and Plant Capacity on Production Cost....., HEX from Dicyclopentadiene HEX from Dicyclopentadiene Effect of Operating Level and Plant Capacity on Production Cost or Dicyclopentadiene Feeds Effect of Feedstock Cost on Production Cost Manufacture of COD-diHEX Adduct COD-DiHEX Adduct Effect of Operating Level and Plant Capacity on Production Cost Triaryl Phosphate Esters Multiproduct Batch Unit xi

6 TABLES Chlorinated Paraffins and Hexachlorocyclopentadiene and Derivatives Summary of Economics.. 9 Phosphate Esters Summary of Economics.. 15 Flame Retardants Used in Plastics-United States Chlorinated Paraffin Plants--United States Chlorinated Paraffin Plants--Japan Phosphate Ester Manufacturers--United States Phosphate Ester Manufacturers--Outside the United States Chlorinated Paraffins Patent Summary Chlorinated Paraffins: 70 Weight Percent Chlorine Major Process Equipment and Utilities Summary Chlorinated Paraffins: 70 Weight Percent Chlorine Stream Flows Manufacture of Chlorinated Paraffins Summary of Waste Products 75 Chlorinated Paraffins: 70 Weight Percent Chlorine Total Capital Investment 80 Chlorinated Paraffins: 70 Weight Percent Chlorine Production Costs Manufacture of HEX Patent Summary Major Process Equipment and Utilities Summary Stream Flows Total Capital Investment 106 Production Costs xiii

7 TABLES REX from Dicyclopentadiene Major Process Equipment and Utilities Summary HEX from Dicyclopentadiene Stream Flows HEX from Dicyclopentadiene Total Capital Investment I-JEX from Dicyclopentadiene Production Costs Manufacture of HEX Adducts Patent Summary Manufacture of REX Adducts Major Process Equipment and Utilities Summary Manufacture of COD-diHEX Stream Flows Manufacture of HEX and HEX Adducts Summary of Waste Products Manufacture of HEX Adducts Total Capital Investment Manufacture of COD-diHEX Production Costs Various HEX Adducts Production Costs Triaryl Phosphate Esters Investment and Production Costs Triaryl Phosphate Esters Effect of Plant Capacity and Raw Materials Unit Costs on Economics Major Process Equipment and Utilities Summary Raw Materials Yields and Requirements Total Capital Investment xiv

8 TABLES 8.4 Capital Investment Requirements B.l B.2 B.3 B.4 B.5 B.6 B.7 B.8 B.9 B.10 2-Ethylhexyl Diphenyl Phosphate Production Costs Production Costs in Multiproduct Batch Unit Typical Data on Chlorowax Typical Data on Cereclor Typical Data on Chlorez Specifications of Technical Grade Hexachlorocyclopentadiene (HEX) Physical Properties of HEX...., Typical Data on Dechlorane 510 and ,. 200 Typical Data on Dechlorane Additives Physical Properties of Triaryl Phosphates Physical Properties of Alkyl Diary1 Phosphates Physical Properties of Halogenated Phosphates Esters,. 204 xv