Bio-Based Fire-Resistant Foam Coating for Safer Substrate Protection
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Solution Overview
Problem
Existing passive fire-resistant structures for substrates associated with crude oil and natural gas extraction and processing, such as phenolic resin-based solutions, pose environmental and health concerns, necessitating a safer and more environmentally friendly alternative.
Innovation Solution
A passive fire-resistant structure comprising a tie coat bonded to a substrate, with a passive fire-resistant foam layer made from a bio-based resin and a hardener, optionally including additives like boric acid, para toluene sulphonic acid, amino functional silane coupling agents, and hollow microspheres, providing enhanced fire resistance and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phenolic resins are used for passive fire-resistant structures, then fire protection performance is achieved, but environmental and health safety concerns arise
Solution Approach 1:
The patent changes the chemical composition parameters of the fire-resistant coating by replacing phenolic resins with bio-based resins (such as lignin, cellulose, or starch derivatives). This substitution maintains the fire protection function while eliminating the harmful properties of phenolic resins, achieving both fire safety and environmental sustainability.
Solution Approach 2:
The invention creates a composite fire-resistant coating system comprising bio-based resin as the binder, combined with fire retardant additives (such as phosphates, nitrates, or borates). This composite formulation achieves the desired fire protection performance while using environmentally benign materials, resolving the contradiction between effectiveness and safety.
2Reliability
If traditional phenolic resin-based fire-resistant structures are used, then fire resistance is provided, but environmental friendliness deteriorates
Solution Approach 1:
The patent modifies the material composition by substituting phenolic resins with bio-based alternatives derived from renewable resources. This parameter change in the chemical composition maintains fire resistance properties while improving environmental compatibility, as bio-based resins are biodegradable and non-toxic.
Solution Approach 2:
The invention employs bio-based resins that are derived from renewable, biodegradable sources, replacing persistent phenolic resins. These bio-based materials provide the necessary fire protection performance while being environmentally friendly and capable of natural degradation, thus improving environmental friendliness without sacrificing fire resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bio-based resin system offers effective fire protection for up to 120 minutes against jet fires and 180 minutes against hydrocarbon pool fires, while being safer and more environmentally friendly than traditional phenolic resin solutions, with improved mechanical strength and thermal resistance.
Implementation Method 1
the passive fire-resistant foam layer is the reaction product of a first material comprising a bio-based resin and a second material comprising a hardener
Implementation Method 2
Passive fire-resistant structures based on phenolic resins are known... provide passive fire protection for on-shore and off-shore substrates... effective fire protection for up to 120 minutes against jet fires and 180 minutes against hydrocarbon pool fires
Data Source
AI summary
A passive fire-resistant structure for a substrate. The structure comprises a tie coat bonded to the substrate and a passive fire-resistant foam layer bonded to the tie coat. The passive fire-resistant foam layer is the reaction product of a first material comprising a bio-based resin and a second material comprising a hardener.