Prometheus Flame Retardant Manufacture

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The project is to construct and prove the design of a unique plant needed to make a new andnovel flame retardant. The concept of the plant and manufacturing process to create thisproduct has been proved at small scale and the objectives of the year will be to build and run 2reactors capable of producing 4 tonnes of product a week, to initiate the sampling and sale ofmaterials to customers and build market awareness.The plant to be constructed has to be able to not only carry out the reaction but also dry theproduct without allowing it to cool and without having to transfer the product to a separatechamber for drying. No plant like this exists.The new flame retardant will be able to provide low smoke, fire safe and fire protectivecomposites for railway, aerospace, military and marine industries without the use ofhazardous flame retardants and without the loss of physical properties. This combination ofabilities makes the product unique. It will not only allow the lightweighting of occupiedvehicles and consequent energy saving without change to current manufacturing proceduresbut also allow composites to be used in new applications.The product creates low smoke and flame retarded rigid and flexible foams particularly forrailway rolling stock, and fire resistant external coatings such as may be applied to vehiclesoperating in tunnels.While the products demonstrate major advantages over the competitive technologies for theintended applications, they impose significant difficulties in the three stage manufacturingprocess. These the project will overcome.The technology uses low cost, sustainable commodity raw materials, combining them in anovel way, with low energy consumption and without production of by products. The finalproducts are insoluble, odourless, non hazardous, and will not alter recycling procedures. Theproducts are entirely polymeric and hence free from the need for REACH registration.