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Traditional intumescent coatings are widely used as passive fire‐protective coatings for steel structures as they are capable of expanding in the range of 20–50 times the original thickness thereby providing excellent insulation. However, the fragile nature of such residue and susceptibility to thermo‐oxidation given their carbonaceous nature are key problematic issues. The concept of in situ ceramization is explored in this work as a means to form inorganic cohesive char with improved rigidity and thermo‐oxidative stability. Coating samples were prepared by incorporating ammonium polyphosphate, talc, Mg(OH)2, and polydimethylsiloxane as additives into acrylic resin at different weight fractions. Thermal analysis and x‐ray diffraction have confirmed the reactions between the additives to form various crystalline magnesium phosphate phases, and to a small extent, silicon phosphate, thereby ensuring the thermo‐oxidative stability of the residue. This is reiterated by the fire performance tests (by exposing the coatings to a temperature profile in a furnace similar to ISO 834 fire curve). Despite the advantages of rigid char and its thermo‐oxidative stability as a result of formation of inorganic phosphates, the lack of swelling has resulted in relatively poor insulation capabilities of the char, and subsequently, compromised the fire protection times (that are in the range of 45–55 min). However, pyrolysis flow combustion calorimeter results of the coatings are promising and have shown a significant drop of up to 70% in the peak of heat release rate values as compared to neat resin.
Traditional intumescent coatings are widely used as passive fire‐protective coatings for steel structures as they are capable of expanding in the range of 20–50 times the original thickness thereby providing excellent insulation. However, the fragile nature of such residue and susceptibility to thermo‐oxidation given their carbonaceous nature are key problematic issues. The concept of in situ ceramization is explored in this work as a means to form inorganic cohesive char with improved rigidity and thermo‐oxidative stability. Coating samples were prepared by incorporating ammonium polyphosphate, talc, Mg(OH)2, and polydimethylsiloxane as additives into acrylic resin at different weight fractions. Thermal analysis and x‐ray diffraction have confirmed the reactions between the additives to form various crystalline magnesium phosphate phases, and to a small extent, silicon phosphate, thereby ensuring the thermo‐oxidative stability of the residue. This is reiterated by the fire performance tests (by exposing the coatings to a temperature profile in a furnace similar to ISO 834 fire curve). Despite the advantages of rigid char and its thermo‐oxidative stability as a result of formation of inorganic phosphates, the lack of swelling has resulted in relatively poor insulation capabilities of the char, and subsequently, compromised the fire protection times (that are in the range of 45–55 min). However, pyrolysis flow combustion calorimeter results of the coatings are promising and have shown a significant drop of up to 70% in the peak of heat release rate values as compared to neat resin.
Introduction. One of the ways to reduce the fire hazard at industrial facilities is the application of intumescent coatings. It is known that intumescent compositions are multicomponent composite materials, whose effectiveness is due to complex chemical transformations of the components of the studied flame retardant exposed to high temperatures. In this regard, the problem of studying the physicochemical processes and thermophysical characteristics of flame retardant thermal expansion materials is in demand and relevant.The purpose of this article is to analyze the thermophysical properties of water- and acrylic compound-based intumescent flame retardants to improve the safety of oil and gas facilities.To accomplish this purpose, the following objectives were attained:studying acrylic dispersion-based intumescent flame retardant materials using methods of thermal analysis;analyzing aqueous dispersion-based intumescent flame retardant materials using methods of thermal analysis;making a comparative analysis of the thermo-oxidative degradation of the studied flame retardant materials.Methods. During the study, thermogravimetric analysis, differential thermogravimetric analysis, differential scanning calorimetry, and quadrupole mass spectrometry were chosen as the main methods.Results. As a result of the studies performed using methods of synchronous thermal analysis of water- and acrylic compound-based intumescent flame retardants, the similarity of ongoing physicochemical processes was identified, including the presence of four main stages of mass loss and a high exothermic effect. This high thermal effect has proven high flammability of the studied flame retardant materials.Conclusions. Following the analysis, the authors have concluded that intumescent flame retardants, containing acrylic vinyl acetate emulsion and aqueous dispersion, begin to lose their performance characteristics, necessary for a flame retardant material, when the temperature reaches approximately ~600 °C.
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