Honeywell Geismar Chlorine and Hydrogen Fluoride Releases

Within a span of less than three years, from October 2021 to June 2024, toxic anhydrous hydrogen fluoride (HF) was released from process equipment in three separate, serious process safety incidents at the Honeywell Performance Materials and Technologies facility in Geismar, Louisiana. All three incidents occurred in Honeywell Geismar’s HFC-245fa unit, which the site refers to as “the 245 unit.” The first incident occurred on October 21, 2021, as Honeywella was attempting to start up a reactor in the 245 unit. A field operator (“Field Operator 1”), who was troubleshooting a no-flow condition to one of the unit’s heat exchangers, smelled a leak of HF. He turned and saw a wisping HF leak from a nearby flanged piping connection. Field Operator 1 requested additional help over the radio, and another operator (“Field Operator 2”) responded. While the two operators were troubleshooting the leaking flange assembly, the gasket between the flanges suddenly failed catastrophically and released toxic HF toward one of them. Field Operator 2 was exposed to the release. His personal protective equipment (PPE) was not sufficient to protect against either skin or respiratory exposure to HF. He was transported to a local hospital, where he passed away later that day. Field Operator 1 was unharmed. Thirty-nine pounds of anhydrous HF were released during the incident, and Honeywell reported $14 million in property damageb resulting from the incident. The second incident occurred on January 23, 2023, also during a startup of the 245 unit. The startup proceeded normally, until a reboiler within the unit suddenly exploded, releasing over 800 pounds of anhydrous HF and over 1,600 pounds of toxic chlorine gas. The reboiler had thinned over time due to corrosion and the failure occurred under otherwise normal operating conditions. No personnel were within the unit, and no injuries resulted from the incident. Honeywell reported $4 million in property damage resulting from this incident, and a complex-wide shelter-in-place order was initiated at the facility, which included two neighbouring manufacturing companies. Local officials also temporarily closed nearby highways. The third incident occurred on June 7, 2024.c Two contract workers were performing planned maintenance work in the 245 unit. The maintenance work involved opening HF piping to replace gaskets. One of the workers opened a flanged connection that, unknown to the worker or to Honeywell, was not adequately emptied of HF prior to the start of the work. Less than one pound of HF was released. Because the worker expected the piping to be empty, he was wearing the minimum level of PPE required by Honeywell. The worker was exposed to HF on his face and was seriously injured. He spent two days recovering in a local hospital.