Top 6 Flame Retardant Additives Used in Polymer Production

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In the world of polymer manufacturing, safety and performance often come down to one key ingredient — the flame retardant additive.

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The top six flame retardant additives used in polymer production are Triethyl Phosphate (TEP), Trioctyl Phosphate (TOP), Ammonium Polyphosphate (APP), Aluminum Hydroxide (ATH), Melamine Cyanurate (MCA), and Zinc Borate (ZB) — each engineered to prevent ignition, slow burning, and minimize smoke generation.

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As modern materials evolve toward lighter and greener solutions, flame retardants are being redefined — no longer just for protection, but also for sustainability. Let’s explore these six key additives, how they work, and where they’re applied in polymer systems.

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1. Triethyl Phosphate (TEP)

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When performance and environmental safety must coexist, Triethyl Phosphate (TEP) is the first choice.

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TEP is a phosphate ester–based flame retardant and plasticizer that offers excellent thermal stability and low toxicity — making it ideal for polyurethane foams, PVC, and coatings.

Key Properties:

• Formula: C₆H₁₅O₄P
• Boiling Point: 215–220°C
• Purity: ≥99%
• Odor: Mild, neutral
• Halogen-Free: Yes

Applications:

• Polyurethane (PU) Foams: Provides self-extinguishing behavior.
• PVC and Coatings: Improves flexibility and flame resistance.
• Adhesives & Sealants: Works as a reactive diluent and plasticizer.

Performance Highlights:
TEP promotes char formation, which acts as a thermal barrier, slowing heat transfer during combustion.
Donghong Chemical’s TEP meets international REACH and RoHS standards, offering clean combustion and low VOC emissions — perfect for sustainable polymer systems.

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2. Trioctyl Phosphate (TOP)

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When high temperature and long-term durability are priorities, Trioctyl Phosphate (TOP) leads the way.

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TOP is a hydrophobic phosphate ester used as both a flame retardant and plasticizer, providing superior heat resistance and oxidation stability.

Technical Details:

• Formula: C₂₄H₅₁O₄P
• Flash Point: ≥190°C
• Purity: ≥99%
• Density: 0.92–0.94 g/cm³

Applications:

• Vinyl Polymers (PVC, PVDF): Enhances flame resistance and flexibility.
• Engineering Plastics: Used in polyamides and epoxy systems.
• Lubricants: Acts as a high-temperature stabilizer.

Performance Advantage:
TOP’s long alkyl chains make it thermally robust and hydrolysis-resistant, suitable for continuous industrial processes.
Donghong Chemical’s TOP phosphate ester is widely used in plastic compounding and electrical insulation materials.

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3. Ammonium Polyphosphate (APP)

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In halogen-free flame retardant systems, Ammonium Polyphosphate (APP) is the essential phosphorus-based choice.

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APP is an inorganic polymeric compound containing phosphorus and nitrogen, which act synergistically to form a protective char layer when exposed to heat.

Chemical Formula: (NH₄PO₃)ₙ
Decomposition Temperature: 250–300°C
Appearance: White powder
Solubility: Slightly soluble in water

Applications:

• Intumescent coatings: Expands to form a heat shield.
• PP and PE Compounds: Common in wire and cable insulation.
• Epoxy Resins: Provides halogen-free flame resistance.

Performance Advantage:
APP is the backbone of intumescent flame retardant (IFR) systems — producing a foamed carbonaceous layer that protects the underlying polymer from oxygen and heat.

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4. Aluminum Hydroxide (ATH)

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For decades, Aluminum Hydroxide (ATH) has been one of the most widely used inorganic flame retardants.

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ATH functions by absorbing heat and releasing water vapor during decomposition, thereby cooling the polymer and diluting flammable gases.

Chemical Formula: Al(OH)₃
Decomposition Temperature: ~200°C
Particle Size: 1–50 µm
Color: White powder

Applications:

• Thermosets (epoxy, polyester): Improves flame and smoke suppression.
• Elastomers: Used in wire and cable sheathing.
• PVC Compounds: Acts as both flame retardant and filler.

Performance Advantage:
ATH offers non-toxic, smoke-suppressing performance and improves mechanical strength when dispersed properly.
For high-temperature polymers, it’s often combined with phosphate esters (TEP or TOP) for synergistic effects.

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5. Melamine Cyanurate (MCA)

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For engineering plastics like nylon and polyamide, Melamine Cyanurate (MCA) is the go-to additive.

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MCA is a nitrogen-based organic flame retardant that releases non-flammable gases and forms char layers during combustion.

Chemical Structure: 2C₃H₆N₆·C₃N₃O₃
Decomposition Temperature: 320–350°C
Form: White crystalline powder

Applications:

• Polyamide (PA6, PA66): Maintains mechanical strength while increasing flame retardancy.
• PBT and PET Compounds: Improves UL-94 V-0 ratings.
• Thermoplastic Polyurethanes (TPU): Low migration and high stability.

Performance Advantage:
MCA is halogen-free, thermally stable, and highly compatible with engineering thermoplastics.
When used with phosphate esters like TEP, it provides synergistic flame retardant effects without compromising polymer clarity.

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6. Zinc Borate (ZB)

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As a multifunctional inorganic additive, Zinc Borate (ZB) offers both flame retardant and smoke-suppressing properties.

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ZB works by releasing crystalline water and forming glass-like barriers at high temperatures, which isolate the polymer from oxygen.

Chemical Formula: 2ZnO·3B₂O₃·3.5H₂O
Decomposition Temperature: 290–420°C
Form: Fine white powder

Applications:

• PVC, PE, and EVA: Works synergistically with ATH or APP.
• Epoxy Resins: Improves thermal stability and smoke suppression.
• Polyolefins: Enhances flame resistance and aging durability.

Performance Advantage:
ZB improves char integrity and reduces dripping during combustion — critical for achieving V-0 ratings in flame retardant testing.

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Dive Deeper: Synergistic Formulation Strategy

The best flame retardant performance often comes from combining multiple additives that address different mechanisms of combustion.

Combination	Synergy Effect	Target Polymer
TEP + ATH	Improved char formation and cooling	PU, PVC
TOP + MCA	Enhanced flame retardancy and mechanical stability	Nylon, PBT
APP + ZB	Strong intumescent effect and smoke suppression	Polypropylene
P204 + TEP	Metal surface protection and flame resistance	Coatings, resins

Donghong Chemical supplies TEP, TOP, and P204 phosphate esters, engineered for use in flame retardant polymer systems that demand both performance and environmental compliance.

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Dive Deeper: Quality and Safety Considerations

When selecting flame retardant additives, always ensure:

• Purity ≥99% for phosphate esters;
• No halogenated compounds (for eco-compliance);
• Low volatility to prevent odor and degradation;
• Thermal stability suited for polymer processing temperatures.

Donghong Chemical ensures each phosphate ester batch meets strict QC criteria, including:

• Acid Value: ≤0.3 mgKOH/g (for TEP, TOP)
• Moisture: ≤0.1%
• Color: ≤30 APHA
• REACH & RoHS certifications

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Conclusion: Safer Polymers Through Smarter Chemistry

The top six flame retardant additives — TEP, TOP, APP, ATH, MCA, and ZB — represent the core of modern polymer fire safety.
Each works through a unique mechanism: forming char, releasing inert gases, or absorbing heat.
And when combined strategically, they deliver powerful, eco-friendly protection for plastics and coatings used in daily life.

With over a decade of manufacturing expertise, Donghong Chemical provides phosphate ester–based flame retardants that help polymer producers achieve high standards in safety, performance, and sustainability.

For technical guidance or bulk purchase inquiries:

📧 Email: dohollchemical@gmail.com
📱 WhatsApp: +86 139 0301 4781

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Donghong Chemical — Leading manufacturer of phosphate esters and surfactant-based flame retardant additives for polymer, coating, and textile industries worldwide.