Utilization of spent coffee grounds as charring agent to prepare flame retardant poly(lactic acid) composites with improved toughness

The objective was to utilize spent coffee grounds (SCG) as charring agent to combine with ammonium polyphosphate (APP) to prepare flame retardant poly(lactic acid) (PLA) composites with improved toughness. PLA/APP-SCG and PLA/APP-SCG/KH560 composites were prepared, and silane coupling agent KH560 was applied to improve particle-matrix interfacial compatibility. The particle-matrix interface, char formation, flame retardancy, mechanical properties and fracture morphology of PLA composites were studied. Results showed that PLA/APP-SCG5% and PLA/APP-SCG20% passed UL-94 V-0 rating, and increase in charred residues was favorable for improving flame retardancy. Improved toughness was also obtained compared to PLA, attributed to debonding of APP from matrix under external force as well as plasticization effect of coffee oil contained in SCG. PLA/APP-SCG5%/KH560 and PLA/APP-SCG20%/KH560 showed smaller elongation at break and impact strength compared to PLA/APP-SCG5% and PLA/APP-SCG20%, respectively. The improved interfacial compatibility was unfavorable for debonding of APP from matrix, and both APP and SCG played the role of enhancing strength, thus decreasing toughness. PLA/APP-SCG/KH560 counterparts were actually set as parallel samples to prove that PLA/APP-SCG composites showed improved toughness with weak interfacial compatibility. This study has provided a practical approach to utilize bio-derived wastes as charring agent to prepare flame retardant PLA composites with enhanced toughness.

The Components' Roles in Thermal Stability and Flammability of Cork Powder

In this study, an analysis of the influence of extractives, suberin and lignocellulosic components on the pyrolysis decomposition and fire reaction mechanisms of a cork oak powder from Quercus suber L. is presented. The summative chemical composition of cork powder was determined. Suberin was the main component at 40% of the total weight, followed by 24% of lignin, 19% of polysaccharides and 14% of extractives. The absorbance peaks of cork and its individual components were further analyzed by means of ATR-FTIR spectrometry. Thermogravimetric analysis (TGA) showed that the removal of extractives from cork slightly increased the thermal stability between 200 °C and 300 °C and led to the formation of a more thermally stable residue at the end of the cork decomposition. Moreover, by removing suberin, a shift of the onset decomposition temperature to a lower temperature was noticed, indicating that suberin plays a major role in enhancing the thermal stability of cork. Furthermore, non-polar extractives showed the highest flammability with a peak of heat release rate (pHRR) of 365 W/g analyzed by means of micro-scale combustion calorimetry (MCC). Above 300 °C, the heat release rate (HRR) of suberin was lower than that of polysaccharides or lignin. However, below that temperature it released more flammable gases with a pHRR of 180 W/g, without significant charring ability, contrary to the mentioned components that showed lower HRR due to their prominent condensed mode of action that slowed down the mass and heat transfer processes during the combustion process.

A review of the extraction methods and advanced applications of lignin-silica hybrids derived from natural sources

The global trend of increasing energy demand along the large volume of wastewater generated annually from the paper pulping and cellulose production industries are considered as serious dilemma that may need to be solved within these current decades. Within this discipline, lignin, silica or lignin-silica hybrids attained from biomass material have been considered as prospective candidates for the synthesis of advanced materials. In this study, the roles and linking mechanism between lignin and silica in plants were studied and evaluated. The effects of the extraction method on the quality of the obtained material were summarized to show that depending on the biomass feedstocks, different retrieval processes should be considered. The combination of alkaline treatment and acidic pH adjustment is proposed as an effective method to recover lignin-silica with high applicability for various types of raw materials. From considerations of the advanced applications of lignin and silica materials in environmental remediation, electronic devices and rubber fillers future valorizations hold potential in conductive materials and electrochemistry. Along with further studies, this research could not only contribute to the development of zero-waste manufacturing processes but also propose a solution for the fully exploiting of by-products from agricultural production.

Synergistic Enhancement of Flame Retardancy Behavior of Glass-Fiber Reinforced Polylactide Composites through Using Phosphorus-Based Flame Retardants and Chain Modifiers

Flame retardancy properties of neat PLA can be improved with different phosphorus-based flame retardants (FRs), however, developing flame retardant PLA-based engineering composites with maintained mechanical performance is still a challenge. This study proposes symbiosis approaches to enhance the flame retardancy behavior of polylactide (PLA) composites with 20 wt% short glass fibers (GF). This was first implemented by exploring the effects of various phosphorus-based FRs up to 5 wt% in neat PLA samples. Among the used phosphorus-based FRs, the use of only 3 wt% of diphosphoric acid-based FR (P/N), melamine coated ammonium polyphosphate (APPcoated), and APP with melamine synergist (APP/Mel) resulted in achieving the V0 value in a vertical burning test in the neat PLA samples. In addition to their superior efficiency in improving the flame retardancy of neat PLA, P/N had the least negative effect on the final mechanical performance of PLA samples. When incorporated in PLA composites with 20 wt% GF, however, even with the use of 30 wt% P/N, the V0 value could not be obtained due to the candlewick effect. To resolve this issue, the synergistic effect of P/N and aromatic polycarbodiimide (PCDI) cross-linker or Joncryl epoxy-based chain-extender (CE) on the flame retardancy characteristics of composites was examined. Due to the further chain modification, which also enhances the melt strength of PLA, the dripping of composites in the vertical burning test terminated and the V0 value could be reached when using only 1 wt% PCDI or CE. According to the scanning electron microscopic analysis, the use of noted chain modifiers further homogenized the distribution and refined the particle size of P/N within the PLA matrix. Hence this could synergistically contribute to the enhancements of the fire resistance performance of the PLA composites. Such incorporation of P/N and chain modifiers further leads to the enhancement of the mechanical performance of PLA composites and hence the resultant product can be proposed as a promising durable bioplastic engineering product where fire risk exists.

Governing effects of melt viscosity on fire performances of polylactide and its fire-retardant systems

Extreme flammability of polylactide (PLA) has restricted its real-world applications. Traditional research only focuses on developing new effective fire retardants for PLA without considering the effect of melt viscosity on its fire performances. To fill the knowledge gap, a series of PLA matrices of varied melt flow index (MFI) with and without fire retardants are chosen to examine how melt viscosity affects its fire performances. Our results show that the MFI has a governing impact on fire performances of pure PLA and its fire-retardant systems if the samples are placed vertically during fire testing. PLA with higher MFI values achieves higher limiting oxygen index (LOI) values, and a lower loading level of fire retardants is required for PLA to pass a UL-94 V-0 rating. This work unveils the correlation between melt viscosity and their fire performance and offers a practical guidance for creating flame retardant PLA to extend its applications.

Multifunctional lignin-based nanocomposites and nanohybrids

Significant progress in lignins valorization and development of high-performance sustainable materials have been achieved in recent years. Reports related to lignin utilization indicate excellent prospects considering green chemistry, chemical engineering, energy, materials and polymer science, physical chemistry, biochemistry, among others. To fully realize such potential, one of the most promising routes involves lignin uses in nanocomposites and nanohybrid assemblies, where synergistic interactions are highly beneficial. This review first discusses the interfacial assembly of lignins with polysaccharides, proteins and other biopolymers, for instance, in the synthesis of nanocomposites. To give a wide perspective, we consider the subject of hybridization with metal and metal oxide nanoparticles, as well as uses as precursor of carbon materials and the assembly with other biobased nanoparticles, for instance to form nanohybrids. We provide cues to understand the fundamental aspects related to lignins, their self-assembly and supramolecular organization, all of which are critical in nanocomposites and nanohybrids. We highlight the possibilities of lignin in the fields of flame retardancy, food packaging, plant protection, electroactive materials, energy storage and health sciences. The most recent outcomes are evaluated given the importance of lignin extraction, within established and emerging biorefineries. We consider the benefit of lignin compared to synthetic counterparts. Bridging the gap between fundamental and application-driven research, this account offers critical insights as far as the potential of lignin as one of the frontrunners in the uptake of bioeconomy concepts and its application in value-added products.

Intumescent Flame Retardant Mechanism of Lignosulfonate as a Char Forming Agent in Rigid Polyurethane Foam

Intumescent flame retardants (IFR) have been widely used to improve flame retardancy of rigid polyurethane (RPU) foams and the most commonly used char forming agent is pentaerythritol (PER). Lignosulfonate (LS) is a natural macromolecule with substantial aromatic structures and abundant hydroxyl groups, and carbon content higher than PER. The flame retardancy and its mechanism of LS as char forming agent instead of PER in IFR formulation were investigated by scanning electron microscopy, thermogravimetric analysis, limiting oxygen index testing and cone calorimeter test. The results showed LS as a char forming agent did not increase the density of RPU/LS foams. LOI value and char residue of RPU/LS foam were higher than RPU/PER and the mass loss of RPU/LS foam decreased 18%, suggesting enhanced thermal stability. CCT results showed LS as a char forming agent in IFR formulation effectively enhanced the flame retardancy of RPU foams with respect to PER. The flame retardancy mechanism showed RPU/LS foam presented a continuous and relatively compact char layer, acting as the effect of the flame retardant and heat insulation between gaseous and condensed phases. The efficiency of different LS ratio in IFR formulation as char forming agent was different, and the best flame retardancy and thermal stability was obtained at RPU/LS1.

Highly Efficient, Environmentally Friendly Lignin-Based Flame Retardant Used in Epoxy Resin

We prepared novel flame retardants with concurrent excellent smoke-suppression properties based on lignin biomass modified by functional groups containing N and P. Each lignin-based flame retardant (Lig) was quantitatively added to a fixed amount of epoxy resin (EP), to make a Lig/EP composite. The best flame retardancy was achieved by a Lig-F/EP composite with elevated P content, achieving a V-0 rating of the UL-94 test and exhibiting excellent smoke suppression, with substantial reduction of total heat release and smoke production (by 46.6 and 53%, respectively). In this work, we characterized the flame retardants and the retardant/EP composites, evaluated their performances, and proposed the mechanisms of flame retardancy and smoke suppression. The charring layer of the combustion residual was analyzed using SEM and Raman spectroscopy to support the proposed mechanisms. Our work provides a feasible method for lignin modification and applications of new lignin-based flame retardants.

The Efficiency of Biobased Carbonization Agent and Intumescent Flame Retardant on Flame Retardancy of Biopolymer Composites and Investigation of their Melt-Spinnability

The objective of this study is to assess the efficiency of biobased carbonization agent in intumescent formulations (IFRs) to examine the flame retardant properties of polylactic acid (PLA) composites and to investigate their melt-spinnability. We used phosphorous-based halogen free flame retardant (FR) and kraft lignin (KL) as bio-based carbonization agent. After melt compounding and molding into sheets by hot pressing various fire related characteristics of IFR composites were inspected and were characterized by different characterization methods. It was fascinating to discover that the introduction of 5–20 wt% FR increased the limiting oxygen index (LOI) of PLA composites from 20.1% to 23.2–33.5%. The addition of KL with content of 3–5 wt% further increased the LOI up to 36.6–37.8% and also endowed PLA/FR/KL composites with improved anti-dripping properties. Cone calorimetry revealed a 50% reduction in the peak heat release rate of the IFR composites in comparison to 100% PLA and confirmed the development of an intumescent char structure containing residue up to 40%. For comparative study, IFR composites containing pentaerythritol (PER) as a carbonization agent were also prepared and their FR properties were compared. IFR composites were melt spun and mechanical properties of multifilament yarns were tested. The analysis of char residues by energy dispersive X-ray spectrometry (EDS) and SEM images confirmed that PLA/FR/KL composites developed a thicker and more homogeneous char layer with better flame retardant properties confirming that the fire properties of PLA can be enhanced by using KL as a carbonization agent.

Influence of Ammonium Polyphosphate/Lignin Ratio on Thermal and Fire Behavior of Biobased Thermoplastic: The Case of Polyamide 11

Flame retardancy of polymers is a recurring obligation for many applications. The development trend of biobased materials is no exception to this rule, and solutions of flame retardants from agro-resources give an advantage. Lignin is produced as a waste by-product from some industries, and can be used in the intumescent formation development as a source of carbon combined with an acid source. In this study, the flame retardancy of polyamide 11 (PA) is carried out by extrusion with a kraft lignin (KL) and ammonium polyphosphate (AP). The study of the optimal ratio between the KL and the AP makes it possible to optimize the fire properties as well as to reduce the cost and facilitates the implementation of the blend by a melting process. The properties of thermal decomposition and the fire reaction have been studied by thermogravimetric analyzes, pyrolysis combustion flow calorimetry (PCFC) and vertical flame spread tests (UL94). KL permits a charring effect delaying thermal degradation and decreases by 66% the peak of heat release rate in comparison with raw PA. The fire reaction of the ternary blends is improved even if KL-AP association does not have a synergy effect. The 25/75 and 33/67 KL/AP ratios in PA give an intumescence behavior under flame exposure.

Recent Advances in Applications of Acidophilic Fungi to Produce Chemicals

Processing of fossil fuels is the major environmental issue today. Biomass utilization for the production of chemicals presents an alternative to simple energy generation by burning. Lignocellulosic biomass (cellulose, hemicellulose and lignin) is abundant and has been used for variety of purposes. Among them, lignin polymer having phenyl-propanoid subunits linked together either through C-C bonds or ether linkages can produce chemicals. It can be depolymerized by fungi using their enzyme machinery (laccases and peroxidases). Both acetic acid and formic acid production by certain fungi contribute significantly to lignin depolymerization. Fungal natural organic acids production is thought to have many key roles in nature depending upon the type of fungi producing them. Biological conversion of lignocellulosic biomass is beneficial over physiochemical processes. Laccases, copper containing proteins oxidize a broad spectrum of inorganic as well as organic compounds but most specifically phenolic compounds by radical catalyzed mechanism. Similarly, lignin peroxidases (LiP), heme containing proteins perform a vital part in oxidizing a wide variety of aromatic compounds with H₂O₂. Lignin depolymerization yields value-added compounds, the important ones are aromatics and phenols as well as certain polymers like polyurethane and carbon fibers. Thus, this review will provide a concept that biological modifications of lignin using acidophilic fungi can generate certain value added and environmentally friendly chemicals.

Investigation of the Flammability and Thermal Stability of Halogen-Free Intumescent System in Biopolymer Composites Containing Biobased Carbonization Agent and Mechanism of Their Char Formation

Starch, being a polyhydric compound with its natural charring ability, is an ideal candidate to serve as a carbonization agent in an intumescent system. This charring ability of starch, if accompanied by an acidic source, can generate an effective intumescent flame retardant (IFR) system, but the performance of starch-based composites in an IFR system has not been tested in detail. Here, we describe a PLA-based IFR system consisting of ammonium polyphosphate (APP) as acidic source and cornstarch as carbon source. We prepared different formulations by melt compounding followed by molding into sheets by hot pressing. The thermal behavior and surface morphology of the composites was investigated by thermogravimetric analysis and scanning electron microscopy respectively. We also conducted limiting oxygen index (LOI), UL-94, and cone calorimetry tests to characterize the flame-retardant properties. Cone calorimetry revealed a 66% reduction in the peak heat release rate of the IFR composites compared to pure PLA and indicated the development of an intumescent structure by leaving a residual mass of 43% relative to the initial mass of the sample. A mechanism of char formation has also been discussed in detail.

Thermal and Mechanical Properties of Silica⁻Lignin/Polylactide Composites Subjected to Biodegradation

In this paper, silica–lignin hybrid materials were used as fillers for a polylactide (PLA) matrix. In order to simulate biodegradation, PLA/hybrid filler composite films were kept in soil of neutral pH for six months. Differential scanning calorimetry (DSC) allowed analysis of nonisothermal crystallization behavior of composites, thermal analysis provided information about their thermal stability, and scanning electron microscopy (SEM) was applied to define morphology of films. The influence of biodegradation was also investigated in terms of changes in mechanical properties and color of samples. It was found that application of silica–lignin hybrids as fillers for PLA matrix may be interesting not only in terms of increasing thermal stability, but also controlled biodegradation. To the best knowledge of the authors, this is the first publication regarding biodegradation of PLA composites loaded with silica–lignin hybrid fillers.

Synthesis of DOPO-HQ-functionalized graphene oxide as a novel and efficient flame retardant and its application on polylactic acid: Thermal property, flame retardancy, and mechanical performance

The fabrication of biodegradable polymer nanocomposites with improved flame retardancy has been an urgent task in practical because of the huge benefits of biodegradable polymers. In this work, 10-(2,5-dihydroxyl phenyl)-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO-HQ)-functionalized graphene oxide (GO) (FGO-HQ) was used as a novel and highly efficient flame retardant (FR) to improve the flame retardancy of polylactide (PLA) nanocomposites. Contributed by the bi-phase flame retardant action, including the physical barrier char in solid phase and the decreased flammable volatiles in gas phase, the resultant PLA/FGO-HQ nanocomposites presented excellent flame resistance at the loading of 6 wt% FR: UL-94 reached V-0 rating; peak heat release rate (PHRR) and total heat release (THR) decreased by 24.0% and 43.0%, respectively; smoke production rate (SPR) and total smoke release (TSR) decreased by 46% and 83%, respectively. For further confirming its flame-resistance mechanism, thermogravimetric analysis/infrared spectrometry (TG-IR) and Fourier transform infrared spectra (FT-IR), scanning electron microscope (SEM), and Raman spectroscopy were employed. Results indicated that the incorporation of FGO-HQ can effectively reduce the evaporation of flammable gaseous product in gas phase through quenching free radicals. Meanwhile, graphitized carbons are formed in the residual char and PLA/FGO-HQ sample can achieve a good thermal stability in the combustion with phosphorus-containing compounds and aromatic structure in the solid phase. Furthermore, the tensile strength of PLA nanocomposites presented good mechanical properties with the addition of FR as well. These results suggested that the incorporation of FGO-HQ FR not only improve the flame retardancy and thermal stability of biodegradable polymer nanocomposites but also without sacrificing their mechanical properties.

Novel flame retardancy effect of phenethyl-bridged DOPO derivative on epoxy resin

A series of flame-retardant epoxy resins (EPs) containing either phenethyl-bridged 9 or 10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide derivative (bisDOPO) were prepared. The flame-retardant properties of bisDOPO on EP composites were characterized by the limiting oxygen index (LOI), the UL-94 vertical burning, and the cone calorimeter test (CCT).The LOI of the EP/bisDOPO composites increased from 21.8% to 38.0%, and the hybrids with the 10 wt% bisDOPO obtained a V-0 rating in the UL94 vertical burning test. The char residue following the CCT showed intumescent structures with continuous and compact surfaces that can effectively suppress the spread of the flame and extinguish the fire. This was confirmed through both visual observation and scanning electron microscopy (SEM) measurements. The flame-retardant mechanism was studied by Fourier transform infrared spectroscope (FTIR), thermogravimetric analysis/infrared spectrometry, SEM/energy-dispersive X-ray, and pyrolysis-gas chromatography/mass spectrometry. Overall, bisDOPO was an effective flame retardant with potential applications within EP.

PLA with Intumescent System Containing Lignin and Ammonium Polyphosphate for Flame Retardant Textile

Using bio-based polymers to replace of polymers from petrochemicals in the manufacture of textile fibers is a possible way to improve sustainable development for the textile industry. Polylactic acid (PLA) is one of the available bio-based polymers. One way to improve the fire behavior of this bio-based polymer is to add an intumescent formulation mainly composed of acid and carbon sources. In order to optimize the amount of bio-based product in the final material composition, lignin from wood waste was selected as the carbon source. Different formulations of and/or ammonium polyphosphate (AP) were prepared by melt extrusion and then hot-pressed into sheets. The thermal properties (thermogravimetric analyses (TGA) and differential scanning calorimetry (DSC)) and fire properties (UL-94) were measured. The spinnability of the various composites was evaluated. The mechanical properties and physical aspect (microscopy) of PLA multifilaments with lignin (LK) were checked. A PLA multifilament with up to 10 wt % of intumescent formulation was processed, and the fire behavior of PLA fabrics with lignin/AP formulation was studied by cone calorimeter.

A novel DOPO-containing flame retardant for epoxy resin

A novel halogen-free flame retardant (6,6′-(((methylenebis(4,1-phenylene))bis(azanediyl))bis((4-hydroxy-3-methoxyphenyl)methylene))bis(6H-dibenzo[c,e][1,2]oxaphosphinine 6-oxide)(DP-DDM))) was synthesized via a one-pot procedure based on the Pudovik reaction between 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide and imine directly resulting from 3-methoxy-4-hydroxybenzaldehyde with 4,4′-methylenedianiline (DDM). The thermal curing behaviors of epoxy resins with different contents of DP-DDM were investigated by differential scanning calorimetry under a nonisothermal condition, aimed to suggest an optimized curing procedure in accordance with the property of DP-DDM. These DP-DDM-modified epoxy thermosets under optimized curing procedure showed high glass transition temperature and thermal degradation activation energy. Moreover, their high flame-retarding performance has been found: the epoxy thermosets with a relatively low addition amount of DP-DDM (on account of the phosphorus content of 0.75 wt%) can reach UL 94 V-0 (Instrumental analysis and measurements) rating with limiting oxygen index value of 34.5.

Flame retardant lignin-based silicone composites

The use of lignin as a filler for polymers to give composites provides both economic advantages and, in some cases, improved flame retardancy and mechanical performance.

Silica/lignosulfonate hybrid materials: Preparation and characterization

The research reported here concerns the synthesis, characterization and potential applications of silica/lignosulfonate hybrid materials. Three types of silica were used (Aerosil®200, Syloid®244 and hydrated silica), along with magnesium lignosulfonate. The effectiveness of the hybrid material synthesis methodology was confirmed indirectly, using Fourier transform infrared spectroscopy, elemental and colorimetric analysis. Dispersive-morphological analysis indicates that the products with the best properties were obtained using 10 parts by weight of magnesium lignosulfonate per 100 parts of Syloid®244 silica. The relatively high thermal stability recorded for the majority of the synthesized products indicates the potential use of this kind of a material as a polymer filler. Results indicating the high electrokinetic stability of the materials are also of great importance. Additionally, the very good porous structure properties indicate the potential use of silica/lignosulfonate systems as biosorbents of hazardous metal ions and harmful organic compounds.

Study of the flame retardancy and thermal properties of unsaturated polyester resin via incorporation of a reactive cyclic phosphorus-containing monomer

A reactive cyclic phosphorus-containing monomer (ethyl acrylate cyclic glycol phosphate; EACGP) was synthesized in a facile way and various amounts of EACGP were combined with unsaturated polyester by radical bulk polymerization. The resulting flame-retardant unsaturated polyester resin (UPR) samples were investigated using thermogravimetric analysis, limiting oxygen index (LOI), and microscale combustion calorimetry tests. Due to the high phosphorus content of EACGP, incorporation of this monomer led to a marked decrease in the peak heat release rate and the total heat release, an increase in the LOI and the combustion char formation. Furthermore, real-time Fourier transform infrared spectroscopy was employed to investigate the thermooxidative degradation behavior of UPRs and the charring effect of EACGP as well as the UPR char morphology was studied, illustrating the flame retardancy mechanism in UPR.

Preparation and properties of flame retardant rigid polyurethane foam with phosphorus–nitrogen intumescent flame retardant

Ethanolamine spirocyclic pentaerythritol bisphosphonate (EMSPB), a novel intumescent flame retardant, was synthesized and used to improve the flame retardancy of rigid polyurethane foam (RPUF). The effects of EMSPB on the flammability, thermal stability, and mechanical properties of RPUF were discussed, respectively. Scanning electron microscopy (SEM) and compression strength tests showed that the EMSPB had favorable compatibility with the RPUF matrix and did not deteriorate the mechanical properties of the RPUF. Flammability of RPUF systems containing various contents of EMSPB was investigated by vertical burning test (UL-94) and limiting oxygen index (LOI) test. Results indicated that when the content of EMSPB was 25 wt%, the LOI of flame retardant RPUF could reach 27.5%, and a UL-94 V-0 rating was achieved. Thermogravimetric analysis showed that RPUF-containing EMSPB had a high yield of residual char at high temperatures, indicating that EMSPB was an effective charring agent. From the SEM observations of the residues of the flame retardant systems burned, the compact charred layers could be seen, which form protective shields to protect effectively the internal structure and inhibited the transmission of heat and heat diffusion during contacting fire.