Fabrication of Polypyrrole-Decorated Tungsten Tailing Particles for Reinforcing Flame Retardancy and Ageing Resistance of Intumescent Fire-Resistant Coatings.

Polypyrrole-decorated tungsten tailing particles (PPY-TTF) were prepared via the in situ polymerization of pyrrole in the presence of tungsten tailing particles (TTF), and then carefully characterized by Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM) and thermogravimetric analysis (TG) analyses. The effect of PPY-TTF on the flame retardancy, smoke suppression property and ageing resistance of intumescent fire-resistant coatings was investigated by a fire protection test, smoke density test and cone calorimeter test. The results show that PPY-TTF exerts excellent cooperative effect on enhancing the flame retardancy and smoke suppression properties of the intumescent fire-retardant coatings, which is ascribed to the formation of more cross-linking structures in the condense phase that enhance the compactness and thermal stability of intumescent char. The cooperative effect of PPY-TTF in the coatings depends on its content, and the coating containing 3 wt% PPY-TTF exhibits the best cooperative effect among the samples, showing a 10.7% reduction in mass loss and 35.4% reduction in flame-spread rating compared to that with 3% TTF. The accelerated ageing test shows that the presence of PPY-TTF greatly slows down the blistering and powdering phenomenon of the coatings, thus endowing the coating with the super durability of fire resistance and smoke suppression property. This work provides a new strategy for the resource utilization of tungsten tailing in the field of flame-retardant materials.