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Industrial inquiries.
This page has a database of industrial inquiries and reports, as well as resources and information about organisations working in this area. Click on an inquiry to go to its detailed page. Please get in touch if there is a report or inquiry you would like to see added or if you find something which needs to be corrected.
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Bio Lab Conyers Chemical Release
Themes
Chemical, Industry, Safety, Release, csb
On Monday September 14, 2020, a thermal decomposition event occurred at the Bio-Lab facility in Conyers, GA. The company is a manufacturer of pool and spa treatment products. The company reported the thermal decomposition of a product that contained chlorine. No injuries were reported however Interstate Highway 20 was closed temporality due to smoke produced from the event.
Issues
Union Carbide Corp. Nitrogen Asphyxiation Incident
Themes
Chemical, Industry, Safety, csb
On March 27, 1998, one worker was killed and another seriously injured when they were asphyxiated by nitrogen at Union Carbide Corporation's Taft/Star Manufacturing Plant in Hahnville, Louisiana. The incident occurred inside a temporary enclosure the workers had erected over the end of large open gas pipe, where the workers were conducting a black light inspection. The workers were not aware that the pipe was being purged with nitrogen, creating an oxygen-deficient atmosphere.
Issues
Confined space
Herrig Brothers Farm Propane Tank Explosion
Themes
Chemical, Industry, Safety, csb
On April 9, 1998, an 18,000-gallon propane tank exploded at the Herrig Brothers farm in Albert City, Iowa. The explosion killed two volunteer firefighters and injured seven other emergency response personnel. Several buildings were also damaged by the blast.
Issues
Morton International Inc. Runaway Chemical Reaction
Themes
Chemical, Industry, Safety, csb
On April 8, 1998, an explosion and fire occurred during the production of Automate Yellow 96 Dye at the Morton International Inc. plant in Paterson, New Jersey. The explosion and fire were the consequence of a runaway reaction, which overpressurized a 2000-gallon chemical vessel and released flammable material that ignited. Nine employees were injured.
Issues
Sonat Exploration Co. Catastrophic Vessel Overpressurization
Themes
Chemical, Industry, Safety, csb
At approximately 6:15 p.m. on March 4, 1998, a catastrophic vessel failure and fire occurred near Pitkin, Louisiana, at the Temple 22-1 Common Point Separation Facility owned by Sonat Exploration Co. Four workers who were near the vessel were killed, and the facility sustained significant damage. The vessel lacked a pressure relief system and ruptured due to overpressurization during start-up, releasing flammable material which ignited.
Issues
Tosco Avon Refinery Petroleum Naphtha Fire
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
On February 23, 1999, a fire occurred in the crude unit at Tosco Corporation. Avon oil refinery in Martinez, California. Workers were attempting to replace piping attached to a 150-foot-tall fractionator tower while the process unit was in operation. During removal of the piping, naphtha was released onto the hot fractionator and ignited. The flames engulfed five workers located at different heights on the tower. Four men were killed, and one sustained serious injuries.
Issues
Management of Change
Themes
Chemical, Industry, Safety, csb
The U.S. Chemical Safety and Hazard Investigation Board (CSB) issues this Safety Bulletin to focus attention on the need for systematically managing the safety effects of process changes in the chemical industry. This bulletin discusses two incidents that occurred in the United States in 1998. Each case history offers valuable insights into the importance of having a systematic method for the management of change (MOC). An MOC methodology should be applied to operational deviations and variances, as well as to preplanned changes—such as those involving technology, processes, and equipment.
Issues
Bethlehem Steel Corporation Gas Condensate Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On February 2, 2001, a fire occurred at Bethlehem Steel Corporation's Burns Harbor mill in Chesterton, Indiana. One Bethlehem Steel millwright and one contractor supervisor died. Four Bethlehem Steel millwrights were injured, one seriously. Workers were attempting to remove a slip blind and a cracked valve from a coke oven gas line leading to a decommissioned furnace. During removal of the valve, flammable liquid was released and ignited.
Issues
Concept Sciences Hydroxylamine Explosion
Themes
Chemical, Industry, Safety, Reactive incident, csb
On February 19, 1999, a process vessel containing several hundred pounds of hydroxylamine exploded at the Concept Sciences Inc. production facility near Allentown, Pennsylvania. Employees were distilling an aqueous solution of hydroxylamine and potassium sulfate, the first commercial batch to be processed at the facility. After the distillation process was shut down, the HA in the process tank and associated piping explosively decomposed, most likely due to high concentration and temperature. Four CSI employees and a manager of an adjacent business were killed. Two CSI employees survived the blast with moderate-to-serious injuries. Four people in nearby buildings were injured. The explosion also caused significant damage to other buildings in the Lehigh Valley Industrial Park and shattered windows in several nearby homes.
Issues
BP Amoco Thermal Decomposition Incident
Themes
Chemical, Industry, Safety, Reactive incident, csb
On March 13, 2001, three people were killed as they opened a process vessel containing hot plastic at the BP Amoco Polymers plant in Augusta, Georgia. They were unaware that the vessel was pressurized. The workers were killed when the partially unbolted cover blew off the vessel, expelling hot plastic. The force of the release caused some nearby tubing to break. Hot fluid from the tubing ignited, resulting in a fire.
Issues
Motiva Enterprises Sulfuric Acid Tank Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On July 17, 2001, an explosion occurred at the Motiva Enterprises refinery in Delaware City, Delaware. A work crew had been repairing a catwalk above a sulfuric acid storage tank farm when a spark from their hot work ignited flammable vapors in one of the tanks. This tank had holes in its roof and shell due to corrosion. The tank collapsed, and one the contract workers was killed; eight others were injured. A significant volume of sulfuric acid was released to the environment.
Issues
Improving Reactive Hazard Management
Themes
Chemical, Industry, Safety, Reactive incident, csb
In August 2000, following its investigation of a serious reactive incident at Morton International, the Board initiated a comprehensive review of reactive hazards nationwide. The purpose of the investigation was to develop recommendations to reduce the number and severity of such incidents.
Issues
Georgia-Pacific Corp. Hydrogen Sulfide Poisoning
Themes
Chemical, Industry, Safety, Release, csb
On January 16, 2002, highly toxic hydrogen sulfide gas leaked from a sewer manway at the Georgia-Pacific Naheola mill in Pennington, Alabama. Several people working near the manway were exposed to the gas. Two contractors from Burkes Construction, Inc., were killed. Eight people were injured--seven employees of Burkes Construction and one employee of Davison Transport, Inc. Choctaw County paramedics who transported the victims to hospitals reported symptoms of hydrogen sulfide exposure.
Issues
Third Coast Industries Petroleum Products Facility Fire
Themes
Chemical, Industry, Safety, csb
On May 1, 2002, a fire erupted at Third Coast Industries in unincorporated Brazoria County, Texas. The facility, which blended and packaged motor oils and other automotive products, was not designed or equipped to prevent the spread of fire. Despite efforts of firefighters, the fire ultimately consumed 1.2 million gallons of combustible and flammable liquids and destroyed the site. One hundred nearby residents were evacuated, a local school was closed, and significant environmental cleanup was necessary due to fumes and runoff. No employees or firefighters were injured during the incident.
Issues
DPC Enterprises Festus Chlorine Release
Themes
Chemical, Industry, Safety, Release, csb
On August 14, 2002, a chlorine transfer hose ruptured during a rail car unloading operation at the DPC Enterprises chlorine repackaging facility near Festus, Missouri. The hose rupture ultimately led to the release of 48,000 pounds of chlorine, causing three workers and 63 residents to seek medical treatment.
Issues
Hazards of Nitrogen Asphyxiation
Themes
Chemical, Industry, Safety, confined space, csb
Every year people are killed by breathing “air” that contains too little oxygen. Because 78 percent of the air we breathe is nitrogen gas, many people assume that nitrogen is not harmful. However, nitrogen is safe to breathe only when mixed with the appropriate amount of oxygen. These two gases cannot be detected by the sense of smell. A nitrogenenriched environment, which depletes oxygen, can be detected only with special instruments. If the concentration of nitrogen is too high (and oxygen too low), the body becomes oxygen deprived and asphyxiation occurs.
Issues
BLSR Operating Ltd. Vapor Cloud Fire
Themes
Chemical, Industry, Safety, Fire, csb
On January 13, 2003, a vapor cloud fire erupted at the BLSR Operating Ltd. oilfield waste disposal facility near Rosharon, Texas, south of Houston. The fire occurred as two vacuum trucks were delivering flammable gas condensate waste for disposal at the facility. Two BLSR employees and one truck driver were fatally burned. Four other workers suffered serious burns but survived.
Issues
Environmental Enterprises Hydrogen Sulfide Release
Themes
Chemical, Industry, Safety, Release, csb
On December 11, 2002, one maintenance employee was overcome when he inhaled hydrogen sulfide gas from a waste processing vessel at Environmental Enterprises, a hazardous waste treatment company in Cincinnati, Ohio. No other injuries or damage were reported, and the injured worker was subsequently pulled to safety.
Issues
Kaltech Industries Waste Mixing Explosion
Themes
Chemical, Industry, Safety, Reactive incident, csb
On April 25, 2002, an explosion occurred at Kaltech Industries, a sign manufacturer in the Chelsea neighborhood of New York City, injuring 36 people seriously enough to seek hospital treatment, including 14 members of the public. The explosion, which was the result of a reaction between waste chemicals, originated in the basement of a mixed-use commercial building and caused damage as high as the fifth floor.
Issues
First Chemical Corp. Reactive Chemical Explosion
Themes
Chemical, Industry, Safety, Reactive incident, csb
On October 13, 2002, a violent explosion occurred in a chemical distillation tower at First Chemical Corporation in Pascagoula, Mississippi, sending heavy debris over a wide area. Three workers in the control room were injured by shattered glass. One nitrotoluene storage tank at the site was punctured by explosion debris, igniting a fire that burned for several hours.
Issues
Catalyst Systems Inc. Reactive Chemical Explosion
Themes
Chemical, Industry, Safety, Reactive incident, csb
On January 2, 2003, a vacuum dryer holding nearly 200 pounds of benzoyl peroxide exploded at the Catalyst Systems Inc. production facility in Gnadenhutten, Ohio. Employees were in the process of drying granular benzoyl peroxide, which is unstable at high concentrations, when the explosion occurred. The explosion and subsequent fire damaged the production facility, and one Catalyst Systems employee received a minor injury while evacuating the building.
Issues
D.D. Williamson & Co. Catastrophic Vessel Failure
Themes
Chemical, Industry, Safety, Release, csb
On the morning of April 11, 2003, one worker was killed at the D.D. Williamson food additive plant in Louisville, Kentucky, when a process vessel became overpressurized and failed catastrophically. The failure caused a release of aqueous ammonia as well as extensive damage to the plant, which manufactures caramel coloring.
Issues
Removal of Hazardous Material from Piping Systems
Themes
Chemical, Industry, Safety, csb
This Safety Bulletin identifies specific tasks that facilities should include in all work activities involving piping or equipment opening to ensure the complete removal of hazardous material. In addition, guidance is provided on implementing generic (plant-wide) procedures for nonroutine work activities.
Issues
Technic Inc. Ventilation System Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On February 7, 2003, a worker was seriously injured in an explosion at Technic Inc. in Cranston, Rhode Island. The explosion occurred during maintenance on a ventilation system connected to multiple chemical reactors, evidently due to an accumulation of hazardous material inside. The plant manufactures precious metal processing chemicals.
Issues
Isotec/Sigma Aldrich Nitric Oxide Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On September 21, 2003, a violent explosion destroyed an underground distillation tower at the Isotec chemical manufacturing plant in Miami Township, Ohio, injuring one worker. The explosion ruptured a carbon monoxide gas pipe and led to a precautionary evacuation of about 2000 residents. The Isotec facility manufactures rare forms of oxygen and nitrogen, known as stable isotopes, which are used in research and medicine.
Issues
West Pharmaceutical Services Dust Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On January 29, 2003, an explosion and fire destroyed the West Pharmaceutical Services plant in Kinston, North Carolina, causing six deaths, dozens of injuries, and hundreds of job losses. The facility produced rubber stoppers and other products for medical use. The fuel for the explosion was a fine plastic powder, which accumulated above a suspended ceiling over a manufacturing area at the plant and ignited.
Issues
CTA Acoustics Dust Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On February 20, 2003, an explosion and fire damaged the CTA Acoustics manufacturing plant in Corbin, Kentucky, fatally injuring seven workers. The facility produced fiberglass insulation for the automotive industry. CSB investigators have found that the explosion was fueled by resin dust accumulated in a production area, likely ignited by flames from a malfunctioning oven. The resin involved was a phenolic binder used in producing fiberglass mats.
Issues
Honeywell Chemical Incidents
Themes
Chemical, Industry, Safety, csb
On July 20, 2003, there was a release of chlorine gas from the Honeywell refrigerant manufacturing plant in Baton Rouge, Louisiana. The accident resulted in the hospitalization of four plant workers and required residents within a half-mile radius to shelter in their homes. On July 29, 2003, a worker was fatally injured by exposure to antimony pentachloride when a gas cylinder released its contents to the atmosphere. On August 13, 2003, two plant workers were exposed to hydrofluoric acid, and one was hospitalized.
Issues
After Katrina: Special Precautions Needed During Oil and Chemical Facility Startup
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
The startup of major processes is a hazardous phase in the operation of oil refineries and chemical plants. Hurricane Katrina has now disrupted production at numerous petrochemical facilities in the Gulf Coast region and caused extensive water and wind damage to facilities in hard-hit areas. Over the coming weeks and months, these facilities will be restarting. This is a time to make sure no more lives are claimed by this tragedy and no further delays occur in the production of essential transportation fuels and chemicals. Facilities should pay particular attention to process safety requirements during this critical period to assure a safe and expeditious return to operation.
Issues
Hayes Lemmerz Dust Explosions and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On the evening of October 29, 2003, a series of explosions severely burned two workers, injured a third, and caused property damage to the Hayes Lemmerz manufacturing plant in Huntington, Indiana. One of the severely burned men subsequently died. The Hayes Lemmerz plant manufactures cast aluminum automotive wheels, and the explosions were fueled by accumulated aluminum dust, a flammable byproduct of the wheel production process.
Issues
Giant Industries Refinery Explosions and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On April 8, 2004, four workers were seriously injured when highly flammable gasoline components were released and ignited at the Giant Industries Ciniza refinery, east of Gallup, New Mexico. The release occurred as maintenance workers were removing a malfunctioning pump from the refinery's hydrofluoric acid (HF) alkylation unit. Unknown to personnel, a shut-off valve connecting the pump to a distillation column was apparently in the open position, leading to the release and subsequent explosions.
Issues
Acetylene Service Company Gas Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On January 25, 2005, a gas explosion killed three workers at the Acetylene Service Company plant in Perth Amboy, NJ. The blast originated in a wooden shed located near six large storage tanks that received liquid waste from the plant's acetylene generating system. The plant produces, repackages, and distributes acetylene used in welding.
Issues
Sterigenics Ethylene Oxide Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
At approximately 3:00 p.m. on August 19, 2004, an explosion occurred inside an ethylene oxide sterilization chamber and an associated thermal oxidizer at the Sterigenics facility in Ontario, California. Four employees suffered minor injuries and the facility was rendered unusable.
Issues
MFG Chemical Inc. Toxic Gas Release
Themes
Chemical, Industry, Safety, Reactive incident, csb
On the evening of April 12, 2004, a chemical reactor overheated at the MFG Chemical manufacturing plant, releasing toxic allyl alcohol vapor. The resulting cloud sent 154 people to a local hospital and forced the evacuation of nearby residents. Vegetation and aquatic life near the plant were killed
Issues
Marcus Oil and Chemical Tank Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On the evening of December 3, a storage tank failed catastrophically at the Marcus Oil and Chemical polyethylene wax facility in Houston. The blast, which was felt up to 20 miles from the plant site, ignited large fires that burned for several hours, and two firefighters were injured during the emergency response. Off-site buildings near the facility - including two churches, a house, and a social club - exhibited structural damage, such as broken windows and cracked walls.
Issues
Praxair Flammable Gas Cylinder Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On June 24, 2005, fire swept through thousands of flammable gas cylinders at the Praxair gas repackaging plant in St. Louis, Missouri. Dozens of exploding cylinders were launched into the surrounding community and struck nearby homes, buildings, and cars, causing extensive damage and several small fires.
Issues
Formosa Plastics Propylene Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
A forklift towing a trailer collided with a line containing highly flammable liquid propylene, causing a release and a vapor cloud explosion. Sixteen workers were injured, the process unit was heavily damaged, and a nearby school was evacuated
Issues
Positive Material Verification: Prevent Errors
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On July 28, 2005, 4 months after a devastating incident in the Isomerization (Isom) Unit that killed 15 workers and injured 180, the BP Texas City refinery experienced a major fire in the Resid Hydrotreater Unit (RHU) that caused a reported $30 million in property damage. One employee sustained a minor injury during the emergency unit shutdown and there were no fatalities.
Issues
Valero Delaware City Refinery Asphyxiation Incident
Themes
Chemical, Industry, Safety, confined space, csb
Two contract employees were overcome and fatally injured by nitrogen as they performed maintenance work near a 24-inch opening on the top of a reactor. One of the workers died attempting rescue.
Issues
Combustible Dust Hazard Investigation
Themes
Chemical, Industry, Safety, Explosion, csb
In 2003, the CSB launched investigations of three major industrial explosions involving combustible powders. These explosions - in North Carolina, Kentucky, and Indiana - cost 14 lives and caused numerous injuries and substantial property losses. The Board responded by launching a nationwide study to determine the scope of the problem and recommend new safety measures for facilities that handle combustible powders.
Issues
DPC Enterprises Glendale Chlorine Release
Themes
Chemical, Industry, Safety, Release, csb
On November 17, 2003, there was a release of chlorine gas from the DPC Enterprises chlorine repackaging facility in Glendale, Arizona, near Phoenix. Fourteen people, including ten police officers, required treatment for chlorine exposure. The release occurred when chlorine vapors from a rail car unloading operation escaped from a system designed to recapture the material, known as a scrubber. Owing to the exhaustion of absorbent chemicals in the scrubber, chlorine gas was released.
Issues
Formosa Plastics Vinyl Chloride Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On April 23, 2004, five workers were fatally injured and two others were seriously injured when an explosion occurred in a polyvinyl chloride (PVC) production unit at Formosa Plastics in Illiopolis, Illinois, east of Springfield. The explosion followed a release of highly flammable vinyl chloride, which ignited. The explosion forced a community evacuation and lighted fires that burned for several days at the plant.
Issues
Bethune Point Wastewater Plant Explosion
Themes
Chemical, Industry, Safety, Explosion, csb
Two municipal workers died and another was seriously injured while attempting to remove a steel canopy above a methanol storage tank at the Bethune Point wastewater plant operated by the City of Daytona Beach. The workers were using a cutting torch that likely ignited methanol vapors from the tank and caused an explosion. The explosion led to the release of the total contents of the tank, approximately 3,000 gallons of methanol.
Issues
BP America (Texas City) Refinery Explosion
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
At approximately 1:20 p.m. on March 23, 2005, a series of explosions occurred at the BP Texas City refinery during the restarting of a hydrocarbon isomerization unit. Fifteen workers were killed and 180 others were injured. Many of the victims were in or around work trailers located near an atmospheric vent stack. The explosions occurred when a distillation tower flooded with hydrocarbons and was overpressurized, causing a geyser-like release from the vent stack.
Issues
Universal Form Clamp Co. Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
One fatality and five injuries resulted from an explosion and fire in a mixing room at the Universal Form Clamp facility. Workers were heating and mixing flammable solvents in an open top tank. During the heating process, there was a sudden evolution of flammable vapors that ignited, resulting in the explosion and fire.
Issues
Partridge Raleigh Oilfield Explosion and Fire
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
Three contractors died and one contractor suffered serious injuries in an explosion and fire at the Partridge-Raleigh Oilfield. The contractors, all employees of Stringer Oilfield Services, were standing on top of a series of four oil production tanks. They were preparing to weld piping to the tanks when a welding tool likely ignited flammable vapors from the tanks.
Issues
Emergency Shutdown Systems for Chlorine Transfer
Themes
Chemical, Industry, Safety, Release, csb
This bulletin compares two chlorine releases investigated by the CSB. In both, a railcar unloading hose failed and chlorine was released. In the first incident, an emergency shutdown system malfunctioned, resulting in a release of 48,000 pounds of chlorine and a significant community impact. In the second, the emergency shutdown system worked to minimize the release, and the community was not impacted.
Issues
Synthron Chemical Explosion
Themes
Chemical, Industry, Safety, Reactive incident, csb
One worker was fatally burned and about a dozen others were injured when a powerful explosion devastated the Synthron Inc. chemical manufacturing facility. CSB investigators believe the explosion was related to the process inside a 1500-gallon batch reactor at the plant, which contained butyl acrylate along with the flammable solvents toluene and cyclohexane.
Issues
EQ Hazardous Waste Plant Explosions and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
Explosions and fire at a hazardous waste facility forced the evacuation of approximately 16,000 residents from Apex, North Carolina, on October 5, 2006. The incident likely began in the oxidizer section of the EQ North Carolina waste facility, where chemicals such as pool chlorination tablets were stored. The fire was allowed to burn out and the facility was destroyed.
Issues
CAI / Arnel Chemical Plant Explosion
Themes
Chemical, Industry, Safety, Explosion, csb
During the early morning hours of November 22, a powerful explosion destroyed the CAI/Arnel ink and paint manufacturing facility in Danvers, Massachusetts. Scores of nearby homes and businesses were damaged, some beyond repair. A number of residents were hospitalized. There were no injuries in the plant, which was unoccupied at the time.
Issues
Barton Solvents Explosions and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On July 17, 2007, explosions and fire erupted at the Barton Solvents facility in Valley Center, Kansas, north of Wichita. The incident led to the evacuation of thousands of residents and resulted in projectile damage offsite, as well as extensive damage to the facility.
Issues
Valero McKee Refinery Propane Fire
Themes
Chemical, Industry, Safety, Fire, csb
On February 16, 2007, a propane fire erupted at the Valero McKee Refinery in Sunray, Texas, north of Amarillo. Three workers suffered serious burns, and the refinery was forced to shut down. The fire began following a leak in the propane deasphalting unit and spread quickly, in part because of the rapid collapse of a major pipe rack carrying flammable hydrocarbons. Some of the rack's support columns had not been fireproofed.
Issues
Barton Solvents Flammable Liquid Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On October 29, 2007, a fire and series of explosions occurred at the Barton Solvents chemical distribution facility in Des Moines, Iowa, . The initial fire started in the packaging area while a 300-gallon portable steel tank was being filled with ethyl acetate, a flammable solvent.
Issues
Little General Store Propane Explosion
Themes
Chemical, Industry, Safety, Explosion, csb
Four people were killed and five others were seriously injured when propane vapors from a storage tank ignited and exploded at the Little General convenience store and gas station in Ghent, West Virginia. Propane was used as fuel inside the building, which was completely destroyed.
Issues
Allied Terminals Fertilizer Tank Collapse
Themes
Chemical, Industry, Safety, csb
On November 12, 2008 a two-million-gallon liquid fertilizer storage tank collapsed at the Allied Terminal distribution facility in Chesapeake, VA. The incident critically injured two contract workers, who were hospitalized. Two members of the public who tried to aid the injured men required treatment likely related to exposure to ammonia vapor from the released fertilizer. The fertilizer over topped a containment dike and flooded sections of a nearby residential neighborhood. At least 200,000 gallons of spilled fertilizer could not be accounted for, and some reached the nearby Elizabeth River, which flows into the Chesapeake Bay.
Issues
T2 Laboratories Inc. Reactive Chemical Explosion
Themes
Chemical, Industry, Safety, Reactive incident, Explosion, csb
On December 19, 2007, four people were killed and 13 others were transported to the hospital when an explosion occured at T2 Laboratories Inc. during the production of a gasoline additive called methylcyclopentadienyl manganese tricarbonyl.
Issues
Imperial Sugar Company Dust Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On February 7, 2008, a huge explosion and fire occurred at the Imperial Sugar refinery northwest of Savannah, Georgia, causing 14 deaths and injuring 38 others, including 14 with serious and life-threatening burns. The explosion was fueled by massive accumulations of combustible sugar dust throughout the packaging building.
Issues
INDSPEC Chemical Corporation Oleum Release
Themes
Chemical, Industry, Safety, Release, csb
On October 11, 2008, a transfer operation overflowed an oleum process tank, filling a vent system and releasing the oleum into a storage building at Indspec Chemical Corporation in Petrolia, Pennsylvania . The release of oleum created a cloud of sulfuric acid mist that filled the building and flowed out into the facility and surrounding community. Plant personnel evacuated the facility, while emergency responders evacuated about 2,500 residents from the towns of Petrolia, Bruin, and Fairview.
Issues
CITGO Refinery Hydrofluoric Acid Release and Fire
Themes
Chemical, Industry, Safety, Release, csb
A fire in the alkylation unit at CITGO's Corpus Christi refinery led to a release of hydrofluoric acid (HF). The alkylation unit makes high-octane blending components for gasoline. One worker was critically burned.
Issues
Packaging Corporation Storage Tank Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, Hot work, csb
On July 29, 2008, three workers died and a fourth was injured when an explosion occurred inside an 80-foot-tall storage tank at the Packaging Corporation of America (PCA) corrugated cardboard mill in Tomahawk, Wisconsin. The workers were on a catwalk above the tank and performing hot work (welding) at the time of the explosion. The storage tank held a mixture of recycled paper pulp and water which the CSB found decomposed to form flammable hydrogen.
Issues
Kleen Energy Natural Gas Explosion
Themes
Chemical, Industry, Safety, Explosion, csb
Six workers were fatally injured during a planned work activity to clean debris from natural gas pipes at Kleen Energy in Middletown, CT. To remove the debris, workers used natural gas at a high pressure of approximately 650 pounds per square inch. The high velocity of the natural gas flow was intended to remove any debris in the new piping. During this process, the natural gas found an ignition source and exploded.
Issues
Veolia Environmental Services Flammable Vapor Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On May 4, 2009, flammable vapors were suddenly released into the atmosphere. The vapors found an ignition source, leading to an explosion and fire that seriously injured two workers and damaged twenty residences.
Issues
Xcel Energy Company Hydroelectric Tunnel Fire
Themes
Chemical, Industry, Safety, confined space, csb
On October 2, 2007, five people were killed and three others injured when a fire erupted 1,000 feet underground in a tunnel at Xcel Energy Company's hydroelectric power plant in Georgetown, Colorado, located approximately 45 miles west of Denver. The fatally injured workers were trapped deep underground during an operation to coat the inside of the tunnel with epoxy using highly flammable solvents. The tunnel is several thousand feet long and connects two reservoirs with electricity-generating turbines.
Issues
Bayer Crop Science Pesticide Waste Tank Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
Two workers were fatally injured when a waste tank containing the pesticide methomyl violently exploded, damaging a process unit at the Bayer CropScience chemical plant in Institute, West Virginia.
Issues
DuPont La Porte Facility Toxic Chemical Release
Themes
Chemical, Industry, Safety, Release, csb
The accident at DuPont’s facility, located east of Houston, killed four workers and injured a fifth when methyl mercaptan, a toxic chemical used in the company’s insecticide and fungicide manufacturing process, was released.
Issues
Texas Tech University Chemistry Lab Explosion
Themes
Chemical, Industry, Safety, Reactive incident, csb
An explosion severely injured a graduate student at Texas Tech University in Lubbock, Texas, in the chemistry department during the handling of a high-energy metal compound, which suddenly detonated. Texas Tech had entered into an agreement with Northeastern University, which holds a contract from the U.S. Department of Homeland Security to study the high-energy materials.
Issues
Oil Tank Safety Study
Themes
Chemical, Industry, Safety, Explosion, csb
On April 13, 2010, the CSB released a safety video, entitled “No Place to Hang Out”. The video tells the story of the tragic deaths of 18-year-old Wade White and 16-year-old Devon Byrd, killed on October 31, 2009, when an oil tank, located in a clearing in the woods near the home of one of the boys in the town of Carnes, Mississippi, suddenly exploded. On April 14, 2010, a fiery explosion took the life of a 21-year-old member of the public in Weleetka, Oklahoma, at an unattended oil and gas production site that was unsecured and likely lacked fire or explosion warning signs.
Issues
Hoeganaes Corporation Fatal Flash Fires
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
Three combustible dust incidents over a six month period occurred at the Hoeganaes facility in Gallatin, TN, resulting in fatal injuries to five workers. The facility produces powdered iron and is located about twenty miles outside of Nashville.
Issues
E. I. DuPont De Nemours Co. Fatal Hotwork Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, Hot work, csb
Two contractors were performing welding atop a 10,000 gallon slurry tank when hot sparks ignited flammable vapors inside the tank, causing an explosion that killed one contractor and seriously injured another.
Issues
Donaldson Enterprises, Inc. Fatal Fireworks Disassembly Explosion and Fire
Themes
Chemical, Industry, Safety, Reactive incident, Explosion, csb
On April 8, an explosion occurred in a fireworks storage facility near Honolulu, Hawaii. According to media reports, the incident occurred in a bunker used to store confiscated fireworks at Donaldson Enterprises, Inc.
Issues
Carbide Industries Fire and Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
Two workers were killed and two others injured as a result of a fire and explosion that occurred at the Carbide Industries facility located in Louisville, KY; the facility produces calcium carbide products.
Issues
NDK Crystal Inc. Explosion with Offsite Fatality
Themes
Chemical, Industry, Safety, Explosion, csb
A large explosion at the NDK America Inc. plant launched debris 300 yards fatally injuring a member of the public. Two individuals were reported to have sustained minor injuries and were treated onsite. The facility is a manufacturer of quartz crystals in Belvidere, Illinois, approximately 60 miles northwest of Chicago.
Issues
Silver Eagle Refinery Flash Fire and Explosion and Catastrophic Pipe Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On the evening of January 12, 2009, 2 refinery operators and 2 contractors suffered serious burns resulting from a flash fire at the Silver Eagle Refinery in Woods Cross, Utah. The accident occurred when a large flammable vapor cloud was released from an atmospheric storage tank, known as tank 105, which contained an estimated 440,000 gallons of light naphtha. The vapor cloud found an ignition source and the ensuing flash fire spread up to 230 feet west of the tank farm. On November 4, 2009, a second accident occurred at the Silver Eagle Refinery in Woods Cross, Utah, when a powerful blast wave - - caused by the failure of a 10 inch pipe - damaged nearby homes.
Issues
Tesoro Anacortes Refinery Fatal Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
An explosion and fire led to the fatal injury of seven employees when a nearly forty-year-old heat exchanger catastrophically failed during a maintenance operation to switch a process stream between two parallel banks of exchangers at the Tesoro refinery in Anacortes, Washington
Issues
AL Solutions Fatal Dust Explosion
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
An explosion ripped through the New Cumberland A.L. Solutions titanium plant in West Virginia on December 9, 2010, fatally injuring three workers. The workers were processing titanium powder, which is highly flammable, at the time of the explosion.
Issues
Key Lessons for Preventing Incidents from Flammable Chemicals in Educational Demonstrations
Themes
Chemical, Industry, Safety, csb
Three accidents involving methanol which injured children during lab demonstrations are examined by the CSB. All the incidents involved demonstrations of flames – usually with a color additive – using methanol as the flammable liquid. In all three cases there was a flash back to the methanol bulk containers, and fire engulfed members of the viewing audience who were not protected by any physical barriers.
Issues
Millard Refrigerated Services Ammonia Release
Themes
Chemical, Industry, Safety, Release, csb
The CSB investigated an anhydrous ammonia release at the Millard Refrigerated Services, a warehouse and distribution center in Theodore, Alabama, 15 miles south of Mobile where more than 130 members of the public sought medical attention and four people remain hospitalized as a result of the uncontrolled ammonia release.
Issues
Chevron Richmond Refinery Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
An August 6, 2012, release of flammable vapor led to a fire at the Chevron Refinery in Richmond, California. The CSB released three investigation reports into this incident - an Interim Report, a Regulatory Report and a Final Report.
Issues
Horsehead Holding Company Fatal Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On July 22, 2010, an explosion and fire killed two workers at the Horsehead Holding Company zinc recycling facility located in Monaca, PA. The facility recycles and purifies zinc through a high temperature distillation process and is located approximately 35 miles north of Pittsburgh.
Issues
Caribbean Petroleum Corporation (CAPECO) Refinery Tank Explosion and Fire
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
A massive fire and explosion sent huge flames and smoke plumes into the air at the Carribean Petroleum Corporation near San Juan, Puerto Rico. The resulting pressure wave damaged surrounding buildings and impacted moving vehicles.
Issues
Macondo Blowout and Explosion
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
On April 20, 2010, a sudden explosion and fire occurred on the oil rig. The accident resulted in the deaths of 11 workers and caused a massive, ongoing oil spill into the Gulf of Mexico. The rig was located approximately 50 miles southeast of Venice, Louisiana, and had a 126-member crew onboard.
Issues
Tesoro Martinez Sulfuric Acid Spill
Themes
Chemical, Industry, Safety, Release, csb
A sulfuric acid spill on February 12, 2014, burned two workers in the refinery’s alkylation unit, who were transported to the nearest hospital burn unit by life flight. The incident occurred when the operators opened a block valve to return an acid sampling system back to service. Very shortly after this block valve had been fully opened, the tubing directly downstream of the valve came apart, spraying two operators with acid.
Issues
AirGas Facility Fatal Explosion
Themes
Chemical, Industry, Safety, Explosion, Fire, csb
On Sunday, August 28, 2016, at approximately 12:10 pm, a nitrous oxide trailer truck exploded at the Airgas manufacturing facility in Cantonment, Florida. The explosion killed the only Airgas employee present and heavily damaged the facility, halting nitrous oxide manufacturing at Cantonment indefinitely.
Issues
ExxonMobil Torrance Refinery Explosion
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
A February 18, 2015, explosion in a gasoline processing unit at the ExxonMobil Refinery in Torrance, CA, led to two workers suffering minor injuries and debris being dispersed into the surrounding community.
Issues
Delaware City Refining Company
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
On Sunday, November 29, 2015, an operator at the Delaware City Refining Company’s (DCRC) Kellogg Alkylation Unit suffered second degree burns to his face and neck areas while performing de-inventorying activities on a vessel in preparation for the removal of a pipe spool from a connected process. This incident follows two other incidents at the same facility which occurred on August 21, and August 28, 2015.
Issues
ExxonMobil Baton Rouge Refinery Chemical Release and Fire
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
On November 22, 2016, an isobutane release occurred in the sulfuric acid alkylation unit at the ExxonMobil Refinery in Baton Rouge, Louisiana which resulted in four serious injuries to workers and injured two others. The incident occurred during minor maintenance on a flammable isobutane line which failed, releasing isobutane into the unit which ignited.
Issues
MGPI Processing, Inc. Toxic Chemical Release
Themes
Chemical, Industry, Safety, Release, csb
On October 21, 2016, a chemical release occurred at the MGPI Processing plant in Atchison, Kansas. MGPI Processing produces distilled spirits and specialty wheat proteins and starches. The release occurred when a chemical delivery truck, owned and operated by Harcros Chemicals, was inadvertently connected to a tank containing incompatible material. The plume generated by the chemical reaction led to a shelter-in-place order for thousands of residents. At least 120 employees and members of the public sought medical attention.
Issues
Packaging Corporation of America Hot Work Explosion
Themes
Chemical, Industry, Safety, Hot work, Explosion, Fire, csb
On February 8, 2017, three contractors were fatally injured and seven contractors sustained injuries in an explosion at the Packaging Corporation of America facility in DeRidder, LA. The fatally injured contractors were conducting hot work activities near a tank which contained a flammable atmosphere and ultimately exploded.
Issues
Arkema Inc. Chemical Plant Fire
Themes
Chemical, Industry, Safety, Fire, Explosion, csb
On August 29, 2017, flooding from Hurricane Harvey disabled the refrigeration system at the Arkema plant in Crosby, TX, which manufactures organic peroxides. The following day people within a 1.5 mile radius were evacuated. As the trailers increased in temperature the peroxides spontaneously combusted on August 31. Officials ignited the remaining trailers, on Sunday, September 3, 2017. The evacuation zone was lifted on September 4, 2017.?
Issues
DuPont Belle Toxic Chemical Release
Themes
Chemical, Industry, Safety, Release, csb
On January 23, there was a release of highly toxic phosgene, exposing a veteran operator at the DuPont facility in Belle, West Virginia and resulting in his death one day later. DuPont officials told the CSB that a braided steel hose connected to a one-ton capacity phosgene tank suddenly ruptured, releasing phosgene into the air.
Issues
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