OxyChem® Dechlorane Plus® Manual Ver: 7-27-07 TABLE OF CONTENTS 1 Introduction 2 Nylon 3 PBT 4 PP 5 ABS 6 Epoxy 7 Wire & Cable 8 Elastomers i Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Dechlorane Plus® (C18H12Cl12) CAS Registry Number 13560-89-9 Dechlorane Plus® 515, 25, and 35 flame retardant additives are highly effective, chlorine-containing, crystalline organic compounds, which have been ground to free-flowing, white powders. They are the same chemical compound, differing only in particle size. The Dechlorane Plus® additives are used as non-plasticizing flame retardants in polymeric systems. Chemical Name: Molecular Weight 1,2,3,4,7,8,9,10,13,13,14,14- dodecachloro- 654 1,4,4a,5,6,6a,7,10,10a,11,12,12a -dodecahydro- 1,4:7,10 - dimethanodibenzo (a,e) cyclooctene 1.1 Specifications: Dechlorane Dechlorane Dechlorane Plus® - 515 Plus® - 25 Plus® - 35 Average Particle Diameter (Microns(1)) 15 Maximum 6 Maximum 3.5 Maximum pH (Methanol-Water Extract) 6.0 - 8.0 6.0 - 8.0 6.0 - 8.0 Volatility, % (4 Hours at 100oC at 5 mm 0.12 Maximum 0.12 Maximum 0.12 Maximum Hg) Color - Rd 92 Minimum 97 Minimum 97 Minimum (1) Micron Values list the average of particle sizes as per the Coulter Counter Method. 1.2 DECHLORANE PLUS® C18H12Cl12 TYPICAL DATA: Appearance White, crystalline, free-flowing solid Chlorine 65.1% Melting Point 350oC (with decomposition) Density 1.8 g/cc Vapor Pressure @200oC 0.006mm of Hg Bulk Density - Dechlorane Plus® 515 and 25 38-42 pounds/cubic foot - Dechlorane Plus® 35 25-30 pounds/cubic foot Recommended Operating Temperature 285oC (545oF) maximum SOLUBILITY: Grams of Dechlorane Plus® Solvent per 100 Grams of Solvent at 25oC Benzene 2.0 Xylene 1.0 Styrene 1.8 Trichloroethylene 1.4 Methyl Ethyl Ketone 0.7 n-Butyl Acetate 0.7 Hexane 0.1 Methyl Alcohol 0.1 1.3 PRODUCT BENEFITS: • Colorability Unlike many other flame retardant additives, Dechlorane Plus® is a fine white powder which easily allows color coding and matching. • Excellent Flame Ratings Formulations may be tailored to meet the most demanding flammability specifications. • Thermal Stability Operating temperatures up to 285oC allow greater ease of processing in a wide variety of polymers. • Excellent Electrical The absence of ionic impurities provides Properties electrical performance that is unsurpassed by other flame retardant additives. • Low Smoke Unlike other halogenated flame retardants, Dechlorane Plus® enhances the formation of an insulative char. This not only inhibits flaming drips and reduces flame propagation, but has the additional benefit of lower smoke generation. • Synergist Options Due to the unique properties of Dechlorane Plus®, cost effective synergist alternatives to antimony trioxide are available. • Inert Filler Dechlorane Plus® has low solubility; it is non-reactive, non-plasticizing, and hydrophobic. • High CTI Performance Comparative tracking index values in excess of 400 volts may be achieved through the use of OxyChem technology. • Cost Effectiveness With a 1.8 specific gravity, Dechlorane Plus® has the cost advantage of comparable brominated flame retardants that range between 2.3 and 3.2. • Technical Expertise Full service technical support to not only back our product and provide recommended starting formulations, but also to assist in your flame retardant formulation success. 1.4 POLYMER SYSTEMS ABS Neoprene Chloroprene Nylon (6, 6/6, 12) DAP PBT EEA Phenolics EPDM Polyester Epoxy Polyethylene EPR Polypropylene EVA Polyurethanes Hypalon® SBR Block Copolymer Hytrel® Silicon Rubber Kraton TPE Natural Rubber TPU High Impact Polystyrene 1.5 DECHLORANE PLUS® Toxicological Summary Toxicity Summary Study Test Species Result _______________________________________________________________________________________________ A. Acute Toxicity 1. Acute Oral Albino Rat LD 25 g/kg 50 2. Acute Dermal Albino Rabbit LD 8 g/kg 50 3. Acute Inhalation Rat LC 2.25 mg/liter 50 B. Eye Irritation Albino Rabbit No effect as an ocular irritant was observed. C. Skin Sensitization Guinea Pig The material is not considered a sensitizer. D. Subchronic Toxicity 1. Oral 90-day Albino Rat The test compound was administered in the diet at 1, 3, and 10% levels. There were no study-related mortalities or untoward behavioral reactions. Growth and food intake were normal. No treatment-related differences between test and control animals were observed in clinical blood chemistry, hematology, urinalysis, gross pathology and histopathology at all feed levels. Slightly increased liver weight was observed at the 10% dietary level but not at the lower levels. 2. Dermal 28-day Albino Rabbit At levels of 500 and 2000 mg/kg Exposure there was practically no irritation with repeated exposure. There were no significant adverse effects noted in the following areas: body weight, hematology, blood chemistry, urinalysis, and pathology. Statistically significant lower weight of gonads was observed in females of both test groups and lower liver weight in females at the 2000 mg/kg level. The differences were within the general range for young rabbits of this strain and age. 1.6 Toxicity Summary Study Test Species Result ________________________________________________________________________________________________ 3. Dust Inhalation Albino Rat Exposure levels were 640 and 1540 28-day Exposure mg/cubic meter. The following parameters were normal: body weight, blood chemistry, clinical chemistry, and urinalysis, and gross pathological examination. Absolute liver and lung weights and lung to body weight ratios were higher than normal in all or some of the test groups. Some histopathological alterations of the lung tissues were observed. These types of changes are frequently observed with exposure to organochlorine compounds and are normally reversible when exposure is terminated. E. Biodegradation Sewage Sludge Dechlorane Plus® is degraded under aerobic conditions but not under anaerobic conditions. F. Aquatic Toxicity Bluegill Sunfish No deaths were observed in 96-hour static and flow through tests at applied concentrations of up to 100 ppm. G. Mutagenicity Dechlorane Plus® did not show a mutagenic response in the following tests: Standard Ames Assay (with and without activation), Ames Assay on Urine from rats treated with Dechlorane Plus®, and Mouse Lymphoma Forward Mutation Assay (with and without activation). 1.7 DECHLORANE PLUS® Combustion Products "In experiments conducted to date on the combustion of polypropylene, nylon, and high impact polystyrene containing Dechlorane Plus®, no regulated chlorodibenzodioxins or furans were detected in combustion products (20 ppb detection limit) when the flame retardant compound was heated from room temperature to 900oC. Additional experiments are in progress. Experiments were conducted by the Institut Fresenius, West Germany, using the "Heraeus" apparatus described by W. Merz, et at in Fresenius Z. Anal. Chem. (1986) 325:449-460 (Springer-Verlag 1986)." More information available upon request. 1.8 FR Nylons Dechlorane Plus® is an excellent flame retardant for all nylons with or without glass fiber reinforcement. UL-94 V-0 ratings are possible to thicknesses of 1/64" (0.4 mm), while maintaining the excellent electrical and physical properties. Many alternative synergists to antimony oxide are available for use when flame retarding nylon with Dechlorane Plus. The synergist selected is a very important factor in determining the physical and electrical properties of the final formulation. Zinc and iron compounds are often used in place of the standard antimony oxide because of their lower cost and the special properties that they contribute. Additionally, synergist mixtures are also useful in obtaining specific properties. Table 2-1 to 2-7 demonstrate the wide range of FR nylon formulations possible with Dechlorane Plus®. Table 2-1 demonstrates the various synergists that may be used with Dechlorane Plus to flame retard nylon 66. While in Table 2-2, the use of mixed synergists gives UL-94 materials with lower loading levels. 2.1 TABLE 2-1 FR-NYLON 66 USING DIFFERENT SYNERGISTS Formulation (Weight %) 1 2 3 4 5 Nylon 66 73 70 73 73 82 Dechlorane Plus® 18 20 18 18 14 Sb2O3 9 10 - - - Zinc Oxide - - 9 - - Zinc Borate - - - 9 - Ferric Oxide - - - - 4 Performance UL-94 1/8" (3.2mm) V-0 V-0 V-0 V-0 V-0 1/16" (1.6mm) V-0 V-0 V-0 V-0 V-0 1/32" (0.8mm) NA* V-0 NC** V-0 V-0 1/64" (0.4mm) NA V-0 NC NC V-0 Tensile Strength (PSI) NA 8406 8696 8840 10435 (MPa) 58 60 61 72 CTI (Kc) (volts) NA 275 600 325 275 * Not Available ** No Class 2.2 TABLE 2-2 FR-NYLON 66 USING MIXED SYNERGISTS Formulation (Weight %) 1 2 3 4 Nylon 66 78 85 70 85 Dechlorane Plus® 16 12 20 10 Sb2O3 2 - - - Zinc Borate 4 1.5 5 2.5 Zinc Oxide - - 5 - Ferric Oxide - 1.5 - - Flamtard S - - - 2.5 Performance UL-94 1/8" (3.2mm) V-0 V-0 V-0 V-0 1/16" (1.6mm) V-0 V-0 V-0 V-0 1/32" (0.8mm) V-0 V-0 V-0 V-1 1/64" (0.4mm) V-0 V-0 V-0 NA Tensile Strength (PSI) 9739 10174 9464 10565 (MPa) 67.2 70.2 65.3 72.9 CTI (Kc) (volts) 450 350 375 575 2.3 In Table 2-3, the efficiency of antimony oxide is compared to a mixed synergist system. There is a 6% reduction in flame retardant package when used in a 25% glass filled system. The most effective single synergist is ferric oxide. With only a 12% flame retardant loading and a synergist loading of 3%, one obtains a V-0 at 1/16 inch. TABLE 2-3 FR-NYLON 66 (25% GLASS-REINFORCED) UL-94 V-0 AT 0.4 MM (1/16 inch) Formulation (Weight %) 1 2 3 4 Nylon 66 49 55 60 60 Fiberglass 25 25 25 25 Dechlorane Plus® 18 16 12 12 Antimony Oxide 8 2 - - Zinc Borate - 2 - 1.5 Ferric Oxide - - 3 1.5 Performance UL-94 1/8" (3.2mm) V-0 V-0 V-0 V-0 1/16" (1.6mm) V-0 V-0 V-0 V-0 1/32" (0.8mm) V-0 V-0 V-0 V-0 1/64" (0.4mm) V-0 V-0 V-0 V-0 Tensile Strength (PSI) 17800 18380 15000 15100 (MPa) 122.6 126.6 103.3 104.0 CTI (Kc) (volts) 225 350 200 200 2.4 Table 2-4 shows the further reduction in flame retardant package that is possible using Dechlorane Plus® in combination with zinc borate and the iron oxides.