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UNITED STATES ANTIMONY CORPORATION (USAC)
has produced various antimony
products for more than
thirty-six years. Production was originally from a large
underground mine reserve of antimony
ore in Thompson
Falls, Montana, and now from other sources. Additional raw material
supplies are being developed by
United
States Antimony, Mexico, S.A. de S.V. (ADM), a USAC joint venture with a
Mexican Corporation, from several
mines in Mexico.
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USAC FACILITIES
The manufacturing facility is located
near the mine at Thompson Falls, Montana, and the
product is warehoused
throughout the United States. The plant is unique, because it has the
capability of treating a diverse supply of raw
materials. Unlike other producers, USAC dedicates a production line to
each different product to insure consistent
quality. Besides Antimony Oxide VF, MP, HT, LT,
Glass Grade, FR Grade and Catalyst Grade, the Company
produces antimony metal, sodium antimonate, and a wide variety of
antimony specialty compounds. USAC has
an ongoing research program for new antimony products development. The
Company has focused on the supply
of antimony products, and has avoided competing with the consumer in
compounding operations. |
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FLAME
RETARDANT (FR) THEORY
Antimony oxide by itself is not a
fire retardant, and the halogens by themselves,
mainly bromine and chlorine, are
weak fire
retardants. However, when they are combined they
become synergistic and are the most effective
and
most widely used flame retardant system for
plastics. Usually three to four parts of
halogenated flame retardants
are used to one
part of antimony oxide on a weight basis. Using
more than the 4:1 ratio offers little additional
protection. The stoichiometric ratio of chlorine
to antimony in antimony trichloride is 3:1.
Formulations in different
applications will
depend on thermal stability, cost, tinting
strength, change in physical properties, smoke
considerations, streaking, blend ability, and
the flame retardant specification.
Two mechanisms exist in the
synergistic system. First is the “free radical
capture” process that takes place in the
vapor
phase. On combustion at a temperature of over
600o F, the halogen forms
hydrochloric or hydrobromic acid
that reacts
with the antimony oxide to form antimony trichloride, antimony oxychloride, antimony
tribromide, or
antimony oxybromide. The flame
retarding action takes place in the vapor stage
above the burning material. It is
thought that
“free radicals” propagate the flame. But, the
antimony trihalides or antimony oxyhalides act
as “free
radical traps” and take up free
radicals. They inhibit ignition and pyrolysis in
the solid, liquid, and vapor phases.
A second process occurs in a
solid phase and is the “char process”. The
antimony oxide promotes the formation
of “char”
(essentially carbon) on the substrate which
reduces volatile gas formation. The barrier
between the
substrate and the vapor phase
reduces the available oxygen to the underlying
substrate. The barrier effect is
obtained by
almost any inert additive. In plastics there is
a cross linking with antimony to produce a more
stable
thermoset polymer. Additionally in the
solid phase, the formation of SbCl3
and SbOCl acts as a dehydrating
agent that
increases charring. Sometimes phosphorous
compounds (TCP), magnesium oxide, alumina trihydrate,
molybdic oxide, zinc borate, or zinc
oxide are used in combination or in place of
antimony oxide to reduce costs,
to increase char
formation, or to reduce smoke. However, the
substitution of the other retardants greatly
reduces
the flame retraces normally rendered
by antimony oxide. Testing of the amounts of the
halogen and antimony
oxide in each formulation
is necessary to optimize the flame retardance
and lower costs. Alumina trihydrate is
not synergistic with halogenated flame retardants.
It functions as a flame retardant by the release
of its water of
hydration and cannot be used in
high temperature processes. Zinc borate, molybdic oxide, zinc oxide, and
magnesium oxide
can be used in conjunction with antimony oxide
to augment char formation and decrease
smoke. Replacement of the antimony oxide to meet a
smoke requirement compromises the flame retardance.
A
relationship exists between particle size and
tinting strength. If the particles are very fine
(less than 300
nanometers) they are below the
visual range and there is no tint strength.
However, within the visual range, the
smaller
the particle size the higher the tint strength.
Or conversely, the larger the particle size, the
lower the tint
strength.
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