The market
The global market for flame retardants and fire retardants was valued at $5.1 billion in 2012 and is projected to reach $7.1 billion in 2017. The market for halogen-free fire-preventing chemicals is already worth $2.72 billion and continues to grow. Health-conscious consumers in Europe and Japan, along with stringent regulations worldwide, are driving hazardous halogenated products out of the market. However, the growth in demand for all flame retardants is driven by China, which is expected to increase demand by more than 13% in the next 12 months. The Asia-Pacific region already accounts for 48% of the global market. Unfortunately, demand for brominated (toxic) flame retardants dominates the Asian market, with sales exceeding $1 billion, and industrialized countries benefit from these exports.
The history of flame-control chemistry dates back to the Egyptians, who soaked wood in alum (hydrated potassium aluminum sulfate) to prevent it from burning. Demand for fire-fighting agents was limited to wood until the introduction of petroleum-based products forced the use of flame retardants as a safety standard. Insurance companies played a central role in promoting their use. Since fire is the fourth leading cause of accidental death, an estimated 300,000 people die each year as parliaments have passed laws mandating these chemicals in sofas, cars, computers, cables, curtains, and many other items. Ironically, the very regulations intended to reduce fire risks introduced toxic chemicals that, even today, are dispersed in the environment. The safety objectives were met, but the health impact proved to be an unintended consequence.
Half of the chemicals used to slow the spread of flames and suppress smoke are mixed into plastics found in cars, airplanes, trains, and homes. The rest are used in textiles, furniture, paper, interior decoration, bedding, lamps, chandeliers, and work clothes. A growing body of research suggests that these flame retardants can cause neurological and reproductive diseases, thyroid dysfunction, and various types of cancer. Based on the results of scientific research, one of the worst molecules (DECA) will be voluntarily phased out by market leaders Albemarle, Chemtura, and ICL Industries by 2013.
Innovation
New regulatory guidelines for reducing toxic chemicals are driving demand for flame retardants that do not bioaccumulate. As governments establish new flammability and smoke standards for a wide range of products, innovators have a unique opportunity to enter the market. Experts predict that nanotechnology will play a key role in improving performance, particularly in creating polymer-clay composites. Mats Nilsson, a Swedish inventor, has devised a completely different solution based on food-grade chemicals. He calls this globally patented discovery "molecular heat eaters" (MHEs), inspired by how warm-blooded animals metabolize food.
Mats recalls the story of his grandfather, a welder who noticed his clothes seemed resistant to sparks and flames in the places where he had accidentally spilled his favorite drink, cider. However, the successful development of this flame retardant is based on more than just an anecdote. The theory behind this breakthrough is that the energy released during an acid-base reaction determines the amount of energy needed to break down the results of a previous reaction. This is an example of physical chemistry. Mats engineered a reaction between an organic acid and an inorganic base, which generates a strong exothermic reaction. As the temperature rises, this creates a fire barrier on the surface, preventing heat from spreading and the fire from escaping.
To create a fire, you need three components: oxygen, heat, and a combustible material. First, the MHE (Mistletoe Hygiene) binds with oxygen to form water using salts, producing positively charged ions (cations). The cells provide carbon to more quickly produce char, a non-combustible material, generating—in the process—CO2, a non-flammable gas. Thus, the oxygen is consumed, and the char covers the surface in an environment of flammable gases. The raw material needed to make the SME (Small Earth Microwave) could come from grape pomace and citrus fruits.
MHE is produced as tiny biodegradable particles, in liquid, gel, or powder form. The minute size of these salts increases the surface area, which multiplies and accelerates the chemical reactions, resulting in a reduction of the amount of flame retardant required.
The first cash flow
The main challenge is optimizing the blending of flame retardants in a wide variety of products. PVC, for example, is rich in chlorine and requires a different concentration of MHE (methyl hydroxide) depending on the additives used to soften the plastic or protect it against ultraviolet radiation, which either increases or enhances its flammability. After years of trial and error, a portfolio of competitive product applications has emerged: polyamide carpets for walls, PVC pipe and carpet backings, flexible polyurethane foam, cellulose for paper, and polystyrene for construction and insulation.
Mats Nilsson then founded Trulstech AB, a Swedish company. He opted for a series of licensing agreements with companies in the United States and Australia. His Swedish partner, Deflamo AB, subsequently entered the secondary market in Stockholm and launched the flame retardant under the brand name Apyrum©. Deflamo has large-scale manufacturing of the operational ingredients to meet industrial demand, and is moving from a wholesaler of the main ingredient to the producer of multi-density fiberboard protected by this flame and natural fire retardant. Deflamo has produced a water-based flame retardant for textiles and paper, a powder for polymers, and a special formulation for impregnating natural fiber textiles.
The opportunity
The innovation described goes beyond simply substituting one chemical for another. It offers the possibility of recycling grape and citrus pomace waste, opening up new opportunities for wine regions; replacing toxic chemicals with food-grade molecules; and transforming a highly centralized industry with few global players into a hub for regional initiatives, supported by a patent portfolio. Furthermore, the range of applications can rapidly expand from aircraft carpets and computer cases to fire extinguishers and environmentally friendly chemicals used in forest fires.
One day, the same technology could even be applied in the mining industry, where sparks cause explosions and necessitate the use of expensive nickel-based equipment. The most intriguing future option is the potential for SME misting to neutralize rifles and cannons. While there is no proof of concept yet, the fact that the product is already competitive in terms of price and performance at the start of its market launch indicates its potential. It is up to entrepreneurs worldwide to build upon existing technology and launch the business.
Videos
For a video demonstration of how this technology works, please click on:
