Flame retardants: Production route
Minerals, bromine or phosphorus: four ways to fight fire
What this tab covers How it is made: the main production routes or, for product families, the main product types and technologies, compared on share of supply, inputs per tonne, plant scale, yield, co-products and unit cost.The family has four main product types. Mineral FRs (ATH, MDH) are cheap and low-toxicity but need high loadings. Halogenated FRs (brominated, some chlorinated) work at low loadings with antimony trioxide, but several are restricted. Phosphorus-based FRs (organophosphates, ammonium polyphosphate, phosphinates) grow as halogen-free options. Nitrogen and boron compounds (melamine cyanurate, zinc borate) are synergists and niche solutions. Producers with their own bromine (Albemarle, ICL, Lanxess) or alumina refinery (Huber, Hindalco) have a raw-material edge.
Routes compared
| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| Mineral FRs (aluminium hydroxide ATH, magnesium hydroxide MDH) | ATH about 38% of volume | about 0.65 t Al2O3 equivalent per t ATH (stoichiometry) | plants of 50-300 kt/yr (indicative) | not applicable | none | lowest-cost FR per kg (indicative) |
| Brominated FRs (DBDPE, TBBPA, brominated polystyrene, polymeric FR) | second largest by volume; 28% in Asia, 11% in North America, 4% in Western Europe | DBDPE is about 82% bromine by weight (stoichiometry) | plants of 10-100 kt/yr (indicative) | not published | HBr recycled | tracks bromine price |
| Phosphorus-based FRs (TCPP, APP, phosphinates, DOPO) | not published; growing | phosphorus from yellow phosphorus or phosphoric acid (indicative) | not published | not published | not published | higher than ATH |
| Chlorinated paraffins and other halogen synergists | not published | chlorine and n-paraffins | many small plants in China and India (indicative) | not published | HCl | low |
How each route works
Mineral FRs (aluminium hydroxide ATH, magnesium hydroxide MDH)ATH is precipitated from Bayer process liquor, washed and milled or precipitated to fine grades; it releases water at about 200 C and cools the flame. MDH works to about 330 C for polypropylene and nylon.
Non-toxic, low smoke; needs 50-65% loading that degrades mechanical properties.
Ceresana (2024); stoichiometry Brominated FRs (DBDPE, TBBPA, brominated polystyrene, polymeric FR)Aromatic compounds are brominated with elemental bromine; TBBPA is made from bisphenol A. Bromine radicals interrupt combustion. Antimony trioxide multiplies the effect.
Efficient at low loading; persistence and dioxin concerns; regulatory risk.
Ceresana (2024); bromine tile Phosphorus-based FRs (TCPP, APP, phosphinates, DOPO)Phosphorus compounds form char and phosphoric acid layers. TCPP is used in PU foam; ammonium polyphosphate in intumescent coatings and PP; aluminium diethylphosphinate (Clariant Exolit OP) in electronics.
Halogen-free; some organophosphates (TCEP) restricted.
indicative Chlorinated paraffins and other halogen synergistsParaffins chlorinated to 40-70% chlorine; used in PVC, rubber and metalworking fluids. Short-chain CPs banned globally in 2017; medium-chain under restriction.
Cheap; persistent pollutant concerns.
indicative Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.