On December 19, 2007, a powerful explosion equivalent to 1400 pounds of TNT occurred at the T2 Laboratories chemical plant in Jacksonville, Florida during the production of methylcyclopentadienyl manganese tricarbonyl (MCMT). The root cause was identified as a lack of knowledge about a second exothermic reaction during the design of the MCMT production line. This led to an inefficient water cooling system and ineffective pressure relief system. The failure of the water cooling system triggered an uncontrollable runaway reaction, increasing temperature and pressure until the reactor exploded. The explosion caused damage up to 1900 feet away and injuries to 32 people, with 4 deaths of T2 employees due to close proximity.
Over the years, there have been numerous gas pipeline incidents which have cause millions of dollars in lost revenue, lives, and property damage. Although some of the responsibility lies with federal or state governments, private and public stakeholders have a responsibility to implement comprehensive health and safety system management and plan emergency response based on capability for readiness and preparedness.
The Bhopal disaster, also referred to as the Bhopal gas tragedy, was a gas leak incident in India, considered the world's worst industrial disaster and The Seveso disaster was an industrial accident.
Which type of Chemistry is responsible to happened this is cleared by Mr. Akash Khojare
1. Soda ash, also known as sodium carbonate, is produced from trona ore through a purification process. It exists in various solid forms and concentrations in solution.
2. Soda ash has maximum solubility of 49.7% at 35.4°C, becoming less soluble at higher temperatures. It hydrates to form different crystalline structures with water.
3. Heat is released when soda ash dissolves in water, reaching a maximum of 135 Btu/lb for a 32% saturated solution. Cooling saturated solutions can cause hydrates to precipitate out.
This document discusses the application of high quality base oils from SK Corporation's UCO lube process to specialty lubricants. It summarizes that the UCO process produces base oils from severely hydrocracked fuels hydrocracker residue that have properties similar to synthetic PAO oils, including high viscosity index, oxidation stability, and low volatility. These base oils can be used in automotive, industrial, and specialty applications like agricultural spray oils, white oils, coning oils, and transformer oils where they provide benefits like improved low-temperature properties and thermal stability compared to conventional base oils. Their main limitation is lower dissolving ability which can be addressed through additive selection or blending with aromatic compounds.
The Flixborough disaster was the largest peacetime explosion in UK history, occurring on June 1st, 1974 at a chemical plant in Flixborough, UK. The explosion killed 28 workers and caused widespread property damage within a 6 mile radius. The public inquiry into the cause determined that the immediate cause was the rupture of a poorly designed 20-inch bypass pipe between two reactors. However, subsequent analysis suggested that the more likely cause was the presence of water in one of the reactors during startup when the stirrer was not operating, allowing an unstable water-cyclohexane azeotrope to form and violently erupt, causing the bypass pipe to fail without high pressure. The disaster highlighted the importance of considering all
Paper and Pulp Industry- Pollution Control TechniquesAsh Hassan
The paper and pulp industry generates significant pollution from its production processes. Wastewater contains high levels of organic materials, dark coloration, and toxic pollutants. Solid wastes like treatment sludges also cause issues due to organic content and trace heavy metals. Air emissions release sulfur oxides, nitrogen oxides, and volatile organic compounds. Modern strategies aim to minimize waste through chemical recycling, improved technologies, and end-of-pipe treatments like biological wastewater treatment before discharge or disposal.
An explosion at a chemical plant in Seveso, Italy in 1976 released toxic clouds containing dioxins over nearby areas. Immediate effects included skin lesions and illness in people and damage to vegetation. Long-term health impacts included liver damage, immune system problems, and increased cancer rates. Soil in contaminated zones was removed and buried in concrete pits as a countermeasure. The disaster led to new regulations like the Seveso Directive to prevent chemical accidents and limit environmental and health impacts.
Anhydrous ammonia is a colorless gas that is stored as a liquid under pressure. It is commonly used as an agricultural fertilizer. When the pressure is released, the liquid vaporizes into a pungent smelling gas. Exposure to ammonia can cause injuries to the eyes, throat, and lungs. It is a polar molecule that readily dissolves in water. The Haber-Bosch process allows industrial fixation of nitrogen from air into ammonia through use of high pressures and temperatures with an iron catalyst. This process is very energy intensive. Fritz Haber's development of this process was important for increasing food production but also enabled Germany to produce explosives and chemical weapons during WWI.
Over the years, there have been numerous gas pipeline incidents which have cause millions of dollars in lost revenue, lives, and property damage. Although some of the responsibility lies with federal or state governments, private and public stakeholders have a responsibility to implement comprehensive health and safety system management and plan emergency response based on capability for readiness and preparedness.
The Bhopal disaster, also referred to as the Bhopal gas tragedy, was a gas leak incident in India, considered the world's worst industrial disaster and The Seveso disaster was an industrial accident.
Which type of Chemistry is responsible to happened this is cleared by Mr. Akash Khojare
1. Soda ash, also known as sodium carbonate, is produced from trona ore through a purification process. It exists in various solid forms and concentrations in solution.
2. Soda ash has maximum solubility of 49.7% at 35.4°C, becoming less soluble at higher temperatures. It hydrates to form different crystalline structures with water.
3. Heat is released when soda ash dissolves in water, reaching a maximum of 135 Btu/lb for a 32% saturated solution. Cooling saturated solutions can cause hydrates to precipitate out.
This document discusses the application of high quality base oils from SK Corporation's UCO lube process to specialty lubricants. It summarizes that the UCO process produces base oils from severely hydrocracked fuels hydrocracker residue that have properties similar to synthetic PAO oils, including high viscosity index, oxidation stability, and low volatility. These base oils can be used in automotive, industrial, and specialty applications like agricultural spray oils, white oils, coning oils, and transformer oils where they provide benefits like improved low-temperature properties and thermal stability compared to conventional base oils. Their main limitation is lower dissolving ability which can be addressed through additive selection or blending with aromatic compounds.
The Flixborough disaster was the largest peacetime explosion in UK history, occurring on June 1st, 1974 at a chemical plant in Flixborough, UK. The explosion killed 28 workers and caused widespread property damage within a 6 mile radius. The public inquiry into the cause determined that the immediate cause was the rupture of a poorly designed 20-inch bypass pipe between two reactors. However, subsequent analysis suggested that the more likely cause was the presence of water in one of the reactors during startup when the stirrer was not operating, allowing an unstable water-cyclohexane azeotrope to form and violently erupt, causing the bypass pipe to fail without high pressure. The disaster highlighted the importance of considering all
Paper and Pulp Industry- Pollution Control TechniquesAsh Hassan
The paper and pulp industry generates significant pollution from its production processes. Wastewater contains high levels of organic materials, dark coloration, and toxic pollutants. Solid wastes like treatment sludges also cause issues due to organic content and trace heavy metals. Air emissions release sulfur oxides, nitrogen oxides, and volatile organic compounds. Modern strategies aim to minimize waste through chemical recycling, improved technologies, and end-of-pipe treatments like biological wastewater treatment before discharge or disposal.
An explosion at a chemical plant in Seveso, Italy in 1976 released toxic clouds containing dioxins over nearby areas. Immediate effects included skin lesions and illness in people and damage to vegetation. Long-term health impacts included liver damage, immune system problems, and increased cancer rates. Soil in contaminated zones was removed and buried in concrete pits as a countermeasure. The disaster led to new regulations like the Seveso Directive to prevent chemical accidents and limit environmental and health impacts.
Anhydrous ammonia is a colorless gas that is stored as a liquid under pressure. It is commonly used as an agricultural fertilizer. When the pressure is released, the liquid vaporizes into a pungent smelling gas. Exposure to ammonia can cause injuries to the eyes, throat, and lungs. It is a polar molecule that readily dissolves in water. The Haber-Bosch process allows industrial fixation of nitrogen from air into ammonia through use of high pressures and temperatures with an iron catalyst. This process is very energy intensive. Fritz Haber's development of this process was important for increasing food production but also enabled Germany to produce explosives and chemical weapons during WWI.
The document discusses different types of coal ash produced during coal combustion, including bed ash and fly ash. Bed ash settles in the furnace of the boiler, while fly ash floats in flue gas. One power plant produces 25% bed ash and 75% fly ash from one unit, while another unit produces 40% bed ash and 60% fly ash. Actual ash production values differ from design values, resulting in higher costs. Reducing ash production according to targets by April and September 2018 through improvements like optimized air flow, furnace draft, and nozzles could save over Rs. 25.5 lakh annually. Required resources and their costs are also outlined.
here we have discuss about Flixborough disaster what are its causes, consequences, how to prevent such kinds of disasters.
it is my college presentation, I have uploaded this document so that it may help other students thank you :)
Sulfuric acid production by contact method (traditional)Mohsen Kianpour
In this slides is about Sulfuric acid production by contact method that is a traditional method to produce sulfuric acid and more about sulfur burning models. In addition you can find more different and new processes to produce it.
The document describes the process for manufacturing urea from ammonia and carbon dioxide. There are six main steps: (1) hydrogen and ammonia production via the Haber process, (2) carbon dioxide removal from the gas stream, (3) shift conversion of carbon monoxide to carbon dioxide, (4) synthesis of ammonia, (5) reaction of ammonia and carbon dioxide to form urea, and (6) concentration and granulation of the urea product. Heat recovery and recycling of water and carbon dioxide are used to improve the efficiency and economics of the process.
This document discusses several chemical disasters including the Bhopal disaster, an IHOP incident, and a UCLA laboratory fire. The Bhopal disaster in 1984 exposed over 200,000 people in India to toxic methyl isocyanate gas, killing thousands. An IHOP incident in 2012 sickened customers when chlorine bleach and ammonia were mixed, releasing chloramine gas. A UCLA laboratory fire in 2008 claimed the life of a researcher when a pyrophoric chemical ignited on contact with oxygen in the air. All of these incidents highlight the importance of safety training, proper equipment, and alternative green chemistries.
What we can do after graduation degree in chemical Engineering?
What is the salary package after CH degree?
What is the scope?
Where we can work?
is work environment safe?
All questions covered in this slide.
CON 123 Session 3 - Typical Raw Mix Designalpenaccedu
The document discusses the raw materials and chemical processes involved in manufacturing Portland cement. It describes the key oxides (calcium, silica, alumina, iron) needed in the raw mix and how the Bogue equations are used to calculate the compounds (C3S, C2S, C3A, C4AF) formed during burning. An example raw mix design is provided along with the calculations to determine the compounds using the Bogue equations on the loss-free chemical analysis. The moduli calculations for lime saturation, silica ratio, and alumina ratio are also outlined. Finally, it briefly describes the wet and dry production processes and shows images of Portland cement clinker.
The chlor-alkali process is an industrial process that uses electrolysis to produce chlorine, sodium hydroxide, and hydrogen from salt water. It involves passing an electric current through a brine solution to drive the following reaction: 2NaCl + 2H2O → 2NaOH + Cl2 + H2. The process was first developed in the 1850s but improved in the 1890s with the mercury cell. Today, membrane and diaphragm cells are more commonly used, accounting for 60% and 14% of European production respectively. The main uses of the products are in polymers, pesticides, antiseptics, acid production, metallurgy, and the paper industry.
Barricade tape, also known as caution tape or warning tape, is a brightly colored plastic tape used to warn people of hazards. It acts as a minor barrier to prevent accidental access to dangerous areas and enhances safety. Common types include construction tape for work zones, hazard tape for toxic chemicals, traffic control tape to redirect vehicles, and police tape to preserve crime scenes. Barricade tape comes in standardized colors according to OSHA and ANSI regulations to indicate different classes of hazards, such as yellow and black for physical dangers or magenta and yellow for radiation risks. It is made of durable materials like polyethylene or nylon and varies in thickness and width depending on the manufacturer and intended use.
The document summarizes the pulp and paper industry processes. Key points include:
- Raw materials like wood, rice straw and cotton are used and undergo cooking, washing, screening and bleaching.
- Wastewater is generated from the cooking, washing, bleaching and papermaking steps.
- Treatment schemes include sedimentation and flocculation to remove impurities from wastewater before discharge.
- Innovative technologies like using enzymes and polymers can improve wastewater treatment and paper quality.
The document describes the chlor-alkali process for producing chlorine and sodium hydroxide through the electrolysis of sodium chloride brine. Key aspects include:
- Sodium chloride brine is purified through processes like precipitation to remove impurities before electrolysis.
- During electrolysis, chlorine gas is produced at the anode, sodium hydroxide at the cathode, and hydrogen as a byproduct. A membrane separates the anode and cathode compartments.
- Weak brine leaving the anode contains dissolved chlorine which is removed through processes like acidification before recycling. Sodium hydroxide product is cooled and may be concentrated.
This document discusses factors that influence the appearance of paint films such as observing distance, resolution of the human eye, and measurement of gloss and texture. Fine structures below 0.1 mm are difficult to perceive even at close distances. The Wave-Scan method uses a CCD camera to measure "dullness" caused by very fine structures. A structure spectrum analysis allows optimization of paint appearance by examining how baking position, flash-off time, film build, steel quality, and application techniques impact the different wavelength ranges.
Seveso Disaster : Chemical Events , Effects and Seveso DirectivesPankaj Kumar
The document summarizes the Seveso disaster that occurred on July 10, 1976 in Seveso, Italy when a chemical plant had an uncontrolled reaction during the production of trichlorophenol, releasing a large cloud of toxic gases and chemicals including dioxins. No one died immediately, but many animals died and thousands more were slaughtered. Residents developed health issues and the area had to be evacuated. The incident led to increased safety regulations and directives for chemical plants in Europe called the Seveso Directives.
This document discusses environment, health, and safety management in the pulp and paper industry. It provides background on the industry and outlines some key hazards. The pulp and paper production process utilizes many chemicals and generates toxic byproducts that can endanger both human health and the environment if not properly managed. Accident risks also exist throughout the process from hazards like rotating equipment, falling objects, fires and explosions. Effective safety and hazard management systems are needed to improve safety and reduce risks in the industry.
This document discusses the range of blending imported coal with domestic coal in India. It outlines the impacts of blending on boiler performance, including changes to ash content and heat distribution. It also describes different blending methodologies like layering in stockyards or blending on conveyors. Experience from utilities already blending coal is discussed, including challenges and solutions. The group recommends that compatibility of coals be ensured before blending and that infrastructure be augmented to support increased coal imports and blending across power stations.
Ball clay is a variety of kaolinite that differs from china clay in having higher plasticity and lower refractoriness. It derives its name from being removed from clay pits in ball-like lumps. Ball clay is mixed with less plastic clays to increase plasticity for use in ceramics like sanitaryware, hotel china, and tiles. Common ceramics uses include vitreous sanitaryware, hotel china, floor and wall tiles, spark plug porcelain, and glass melting pot bodies.
The document analyzes an acrylic reactor runaway and explosion accident that occurred in Taiwan in 2001. It provides the following key details:
- The accident was caused by a runaway polymerization reaction in a 6-ton reactor containing various acrylic monomers and peroxide initiator. As the temperature rapidly increased, vapors were released and ignited, causing an explosion.
- Investigations revealed the temperature inside the reactor increased from 60°C to 170-210°C at a maximum rate of 192 K/min during the runaway. The explosion was estimated to be equivalent to 1000 kg of TNT.
- Tests were performed to analyze the causes and hazards of such runaways. Differential scanning
The document discusses automation and safety considerations for the polymerization of vinyl chloride monomer (VCM) in polyvinyl chloride (PVC) production. VCM is flammable and toxic, and the exothermic polymerization reaction must be carefully controlled to prevent runaway reactions. Hazards include fires, explosions, and toxic emissions. A hazard assessment identifies scenarios like cooling failure, overfilling, and loss of agitation that could lead to runaway. Prevention strategies include alarms, addition of chemical inhibitors, and automatic depressurization of reactors in emergencies.
The document discusses different types of coal ash produced during coal combustion, including bed ash and fly ash. Bed ash settles in the furnace of the boiler, while fly ash floats in flue gas. One power plant produces 25% bed ash and 75% fly ash from one unit, while another unit produces 40% bed ash and 60% fly ash. Actual ash production values differ from design values, resulting in higher costs. Reducing ash production according to targets by April and September 2018 through improvements like optimized air flow, furnace draft, and nozzles could save over Rs. 25.5 lakh annually. Required resources and their costs are also outlined.
here we have discuss about Flixborough disaster what are its causes, consequences, how to prevent such kinds of disasters.
it is my college presentation, I have uploaded this document so that it may help other students thank you :)
Sulfuric acid production by contact method (traditional)Mohsen Kianpour
In this slides is about Sulfuric acid production by contact method that is a traditional method to produce sulfuric acid and more about sulfur burning models. In addition you can find more different and new processes to produce it.
The document describes the process for manufacturing urea from ammonia and carbon dioxide. There are six main steps: (1) hydrogen and ammonia production via the Haber process, (2) carbon dioxide removal from the gas stream, (3) shift conversion of carbon monoxide to carbon dioxide, (4) synthesis of ammonia, (5) reaction of ammonia and carbon dioxide to form urea, and (6) concentration and granulation of the urea product. Heat recovery and recycling of water and carbon dioxide are used to improve the efficiency and economics of the process.
This document discusses several chemical disasters including the Bhopal disaster, an IHOP incident, and a UCLA laboratory fire. The Bhopal disaster in 1984 exposed over 200,000 people in India to toxic methyl isocyanate gas, killing thousands. An IHOP incident in 2012 sickened customers when chlorine bleach and ammonia were mixed, releasing chloramine gas. A UCLA laboratory fire in 2008 claimed the life of a researcher when a pyrophoric chemical ignited on contact with oxygen in the air. All of these incidents highlight the importance of safety training, proper equipment, and alternative green chemistries.
What we can do after graduation degree in chemical Engineering?
What is the salary package after CH degree?
What is the scope?
Where we can work?
is work environment safe?
All questions covered in this slide.
CON 123 Session 3 - Typical Raw Mix Designalpenaccedu
The document discusses the raw materials and chemical processes involved in manufacturing Portland cement. It describes the key oxides (calcium, silica, alumina, iron) needed in the raw mix and how the Bogue equations are used to calculate the compounds (C3S, C2S, C3A, C4AF) formed during burning. An example raw mix design is provided along with the calculations to determine the compounds using the Bogue equations on the loss-free chemical analysis. The moduli calculations for lime saturation, silica ratio, and alumina ratio are also outlined. Finally, it briefly describes the wet and dry production processes and shows images of Portland cement clinker.
The chlor-alkali process is an industrial process that uses electrolysis to produce chlorine, sodium hydroxide, and hydrogen from salt water. It involves passing an electric current through a brine solution to drive the following reaction: 2NaCl + 2H2O → 2NaOH + Cl2 + H2. The process was first developed in the 1850s but improved in the 1890s with the mercury cell. Today, membrane and diaphragm cells are more commonly used, accounting for 60% and 14% of European production respectively. The main uses of the products are in polymers, pesticides, antiseptics, acid production, metallurgy, and the paper industry.
Barricade tape, also known as caution tape or warning tape, is a brightly colored plastic tape used to warn people of hazards. It acts as a minor barrier to prevent accidental access to dangerous areas and enhances safety. Common types include construction tape for work zones, hazard tape for toxic chemicals, traffic control tape to redirect vehicles, and police tape to preserve crime scenes. Barricade tape comes in standardized colors according to OSHA and ANSI regulations to indicate different classes of hazards, such as yellow and black for physical dangers or magenta and yellow for radiation risks. It is made of durable materials like polyethylene or nylon and varies in thickness and width depending on the manufacturer and intended use.
The document summarizes the pulp and paper industry processes. Key points include:
- Raw materials like wood, rice straw and cotton are used and undergo cooking, washing, screening and bleaching.
- Wastewater is generated from the cooking, washing, bleaching and papermaking steps.
- Treatment schemes include sedimentation and flocculation to remove impurities from wastewater before discharge.
- Innovative technologies like using enzymes and polymers can improve wastewater treatment and paper quality.
The document describes the chlor-alkali process for producing chlorine and sodium hydroxide through the electrolysis of sodium chloride brine. Key aspects include:
- Sodium chloride brine is purified through processes like precipitation to remove impurities before electrolysis.
- During electrolysis, chlorine gas is produced at the anode, sodium hydroxide at the cathode, and hydrogen as a byproduct. A membrane separates the anode and cathode compartments.
- Weak brine leaving the anode contains dissolved chlorine which is removed through processes like acidification before recycling. Sodium hydroxide product is cooled and may be concentrated.
This document discusses factors that influence the appearance of paint films such as observing distance, resolution of the human eye, and measurement of gloss and texture. Fine structures below 0.1 mm are difficult to perceive even at close distances. The Wave-Scan method uses a CCD camera to measure "dullness" caused by very fine structures. A structure spectrum analysis allows optimization of paint appearance by examining how baking position, flash-off time, film build, steel quality, and application techniques impact the different wavelength ranges.
Seveso Disaster : Chemical Events , Effects and Seveso DirectivesPankaj Kumar
The document summarizes the Seveso disaster that occurred on July 10, 1976 in Seveso, Italy when a chemical plant had an uncontrolled reaction during the production of trichlorophenol, releasing a large cloud of toxic gases and chemicals including dioxins. No one died immediately, but many animals died and thousands more were slaughtered. Residents developed health issues and the area had to be evacuated. The incident led to increased safety regulations and directives for chemical plants in Europe called the Seveso Directives.
This document discusses environment, health, and safety management in the pulp and paper industry. It provides background on the industry and outlines some key hazards. The pulp and paper production process utilizes many chemicals and generates toxic byproducts that can endanger both human health and the environment if not properly managed. Accident risks also exist throughout the process from hazards like rotating equipment, falling objects, fires and explosions. Effective safety and hazard management systems are needed to improve safety and reduce risks in the industry.
This document discusses the range of blending imported coal with domestic coal in India. It outlines the impacts of blending on boiler performance, including changes to ash content and heat distribution. It also describes different blending methodologies like layering in stockyards or blending on conveyors. Experience from utilities already blending coal is discussed, including challenges and solutions. The group recommends that compatibility of coals be ensured before blending and that infrastructure be augmented to support increased coal imports and blending across power stations.
Ball clay is a variety of kaolinite that differs from china clay in having higher plasticity and lower refractoriness. It derives its name from being removed from clay pits in ball-like lumps. Ball clay is mixed with less plastic clays to increase plasticity for use in ceramics like sanitaryware, hotel china, and tiles. Common ceramics uses include vitreous sanitaryware, hotel china, floor and wall tiles, spark plug porcelain, and glass melting pot bodies.
The document analyzes an acrylic reactor runaway and explosion accident that occurred in Taiwan in 2001. It provides the following key details:
- The accident was caused by a runaway polymerization reaction in a 6-ton reactor containing various acrylic monomers and peroxide initiator. As the temperature rapidly increased, vapors were released and ignited, causing an explosion.
- Investigations revealed the temperature inside the reactor increased from 60°C to 170-210°C at a maximum rate of 192 K/min during the runaway. The explosion was estimated to be equivalent to 1000 kg of TNT.
- Tests were performed to analyze the causes and hazards of such runaways. Differential scanning
The document discusses automation and safety considerations for the polymerization of vinyl chloride monomer (VCM) in polyvinyl chloride (PVC) production. VCM is flammable and toxic, and the exothermic polymerization reaction must be carefully controlled to prevent runaway reactions. Hazards include fires, explosions, and toxic emissions. A hazard assessment identifies scenarios like cooling failure, overfilling, and loss of agitation that could lead to runaway. Prevention strategies include alarms, addition of chemical inhibitors, and automatic depressurization of reactors in emergencies.
T2 Laboratories experienced a chemical explosion in 2007 due to a runaway exothermic reaction during the production of MCMT. The explosion was caused by a loss of sufficient cooling during the process, which led to an uncontrollable increase in pressure and temperature inside the reactor. The explosion damaged the facility equivalent to 1400 pounds of TNT. The study found that T2 Laboratories lacked proper process safety information and hazard analysis, did not understand the chemistry's potential for runaway reactions, and had an improperly designed emergency relief system. The incident highlights the importance of thoroughly understanding chemical reactions and implementing safety systems, such as cooling and pressure controls, when scaling up chemical production.
The document discusses microreaction technology and microreactors. It explains that microreactors are small, miniaturized reaction systems with channel dimensions typically less than 1000 μm that offer advantages like optimal mixing, efficient heat transfer, small volumes, and safer handling of hazardous chemicals. Microreactors first emerged in the 1990s and have various applications in chemistry, pharmaceuticals, and molecular biology by producing products in larger volumes. Key features of microreactors include precise control of reaction conditions and scaling reactions up through numbering up microreactors rather than increasing the size of individual reactors.
A presentation on an Air Pollution Episode called " Bhopal Gas Tragedy". Its causes, effects on humans, animals, plants and environment. Measures taken thereafter to overcome the situation
This research paper introduces the Bhopal plant gas tragedy disaster that happened in India, 1984:
- Major causes and errors leading to multiple failures of the chemical plant are elaborated.
- Main catastrophic consequences are discussed and classified in terms of casualties and fatalities, acute and chronic health effects, and toxic effects on soil and water.
- Rehabilitation procedures adopted after the incident.
- Preventive barriers that could have been adopted in order to reduce the likelihood of the disaster occurrence.
If accidents are to be reduced, this needs maximum attention and an optimum risk management system.
The document summarizes techniques for extracting essential oils from basil using microwave-assisted extraction. It describes how microwave heating selectively heats materials through molecular interactions, allowing extractions to be completed faster than conventional methods while avoiding thermal degradation. The techniques discussed are solvent-free microwave extraction of fresh basil and microwave hydrodistillation of dried basil. Results show the new techniques produce higher quality oils in shorter times compared to traditional hydrodistillation. The system allows scalable extractions and precise control over extraction parameters.
Change your life, this is the motto of PEL. PEL is a famous company in Pakistan which is famous for its Home appliances like, Refrigerator, Air conditioner, Microwave oven, Deep freezer, and water dispenser.Their R&D department is the best.
process techniques - introduction slide.pdfomerozdogann
This document provides an introduction to process technology. It discusses key topics including:
- Process technology is applied in the chemical process industry to convert raw materials into useful products. Common raw materials include oil, gas, air, water, and minerals.
- Processes involve multiple unit operations working together, such as heating, cooling, mixing, separation processes. Larger scale operations are generally more cost effective.
- Fundamental transport processes that occur in unit operations include momentum, heat, and mass transfer. Reaction and use of catalysts also allow for chemical conversions.
- Proper documentation of processes is important for safety, optimization, and regulatory compliance.
IRJET- Design and Analysis of Heat Exchanger with Nano CoatingIRJET Journal
The document discusses designing and analyzing a heat exchanger with nano coating. It aims to determine which of two materials, magnesium zirconium oxide or nickel chromium alloy, is better suited for nano coating on a heat exchanger surface to increase heat transfer rate. The coating process involves blasting the surface followed by thermal spray application of the nano material. Properties of both materials are provided. The heat exchanger design is created using CATIA software. Analysis will be done using ANSYS to find the most suitable coating material.
The document provides details about the internship of Farooque Ahmed Mahar in the Services Department of Sui Southern Gas Company (SSGC). It describes the various systems maintained by the Services Department including HVAC, elevators, power generation, and electrical supply. HVAC oversees chillers, fire hydrants, water filtration, and air handling units. Power is primarily generated through Waukesha, Guascor, and Caterpillar generators running on natural gas. KE supply is used as a backup after office hours.
This document discusses applications of fluidized bed technology beyond combustion and gasification. It provides examples such as fluid catalytic cracking (FCC) for petroleum refining, reduction of iron ores, and production of melamine. FCC is described as one of the largest applications of fluidized bed technology and catalysts. The process involves cracking of hydrocarbons over a catalyst in a fluidized bed reactor and regenerator. Other examples discussed include fluidized bed applications in flue gas cleaning, production of titanium oxide, roasting of sulfide ores, and drying of coal.
Fabricate Silicon Device and ITO Device in Micro Fabrication Laboratory under...Jiemin Zhang
The document describes fabricating two devices - a silicon device and an ITO device - in a microfabrication laboratory under supervision. It details the cleaning, oxidation, deposition, photolithography, and testing steps used. The goal was to gain experience using the facilities and characterize the resistance of thin film materials. Standard clean room procedures were followed for processes like RCA cleaning, thermal oxidation, sputtering, spin coating, and ellipsometry thickness measurement.
Applications of Nanotechnology in domestic refrigeration Amir Firdoos
1. The document compares the performance of refrigeration systems using nanofluids. It finds that nanofluids increase the coefficient of performance (COP) and thermal conductivity of refrigerants.
2. Simulation results show COP increases up to 14% with added nanoparticles like SiO2, Al2O3, TiO2, and CuO. However, COP gains level off after a certain concentration threshold.
3. Thermal conductivity also increases with nanoparticles, offering benefits like higher cooling capacity and lower power needs.
Ureap lant energy improved with operation philosophyand reactor internalsPrem Baboo
The energy of H.P. loop directly proportional to the pressure of h.p loop. The H.P loop is the heart of urea plants. Conversion of urea depends upon N/C & H/C ratio, reactor internal construction, i.e. configuration of trays, reactants mixing phenomenon, flow pattern etc. other than pressure. In conventional plants there was too much pressure of the reactors for higher urea conversion. Now philosophy has been changed our mind concentrated on flow pattern of the fluid dynamics and internals of the reactors. The performances of Urea Reactors can be improved by the application of the latest generation of internals like HET, Vortex mixture and conversion booster. As a consequence, the HET & Vortex mixture can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a retrofit design. The increase in the efficiency has permitted direct benefits to the overall day-by-day performances of the units, thus allowing lower energy consumption and a reduced environmental impact. The present paper based on these facts and how to improve energy by changing internals, operational parameters like molar ratio, recycling of water in the system, pressure & temperature of the system to improve energy and equipment’s life. The most important of these consists of a sharp reduction in specific steam consumption. The fluid-dynamics of a urea reactor can be significantly improved by the introduction of the latest generation of internals. e.g. Super cup trays, Vortex mixture, NIIK internals, siphon jet trays etc. No pressure drop observed because the gas phase directly converted to liquid phase the driving force compensates the pressure drop and No load limitation.
The document describes the 1984 Bhopal gas tragedy where toxic methyl isocyanate gas was released from a Union Carbide India pesticide plant. An operator accidentally opened a valve that allowed water into a tank containing methyl isocyanate, causing an exothermic reaction that increased pressure and burst a safety disc, releasing the toxic gas. Scrubbers meant to render the gas harmless were not working, and the flare designed to burn vented gases was out of service, allowing the deadly cloud to spread over the town.
The document provides details about the internship of Farooque Ahmed Mahar in the Services Department of Sui Southern Gas Company (SSGC) from May 12 to August 6, 2021. It describes the various systems maintained by the Services Department, including heating, ventilation, and air conditioning (HVAC), elevators, water filtration, power generation, and electrical supply from K-Electric. The internship aimed to provide learning opportunities and help the intern gain familiarity with different machines and systems used at SSGC.
IRJET- IC Engine Waste Heat Recovery SystemsIRJET Journal
The document summarizes various waste heat recovery systems for internal combustion engines. It discusses organic Rankine cycle systems and thermoelectric generator systems for recovering heat from engine exhaust gases. Organic Rankine cycle systems use a turbine to convert the thermal energy of exhaust gases into electricity via a Rankine cycle. Thermoelectric generators use the Seebeck effect to directly convert a temperature difference into electricity. The document analyzes the advantages and disadvantages of these waste heat recovery technologies and their potential to improve engine efficiency and reduce emissions.
2. Page | 1
T2 Laboratories Explosion Report
Group Number 3
Hansen Lim 21528136
Chun Ho Mah 21799814
Wai Hoe Loke 21979936
Ainsley Ng 22103627
Ken Yoong Fong 21640556
MEC4427 System Integrity and Maintenance
3. Page | 2
Table of Contents
Summary.................................................................................................................................................3
1.0 Introduction ................................................................................................................................4
2.0 Failure Analysis ...........................................................................................................................5
2.1 Sequence of events.................................................................................................................6
2.2 Failure Modes and Effects (Criticality) Analysis (FMECA) and Fault Tree Analysis (FTA)........6
2.3 Root cause of failure...............................................................................................................8
2.4 Theory behind physical failure mechanism ..........................................................................10
2.4.1 Explosion by fast fracture .............................................................................................10
2.4.2 Micromechanisms of fast fracture................................................................................11
3.0 Consequences...........................................................................................................................12
4.0 Recommendation......................................................................................................................15
5.0 Significance of event.................................................................................................................16
5.1 Comparison with similar events............................................................................................16
5.2 Learning.................................................................................................................................17
Conclusions ...........................................................................................................................................18
References ............................................................................................................................................19
4. Page | 3
Summary
On 19 December 2007, a powerful explosion equivalent to 1400 pounds of TNT and a massive fire
occurred in Jacksonville, Florida at T2 laboratories. This report titled “T2 Laboratories Explosion”
describes the sequence of events, consequences and the root causes of the disaster in detail. T2
Laboratories Inc. is a chemical processing facility that specialized in the design and manufacture of
chemicals for gasoline additives. It began full scale production of methylcyclopentadienyl
manganese tricarbonyl (MCMT) in 2004 and continued producing MCMT until its 175th batch in
2007 when the disaster happened.
The impact of explosion travelled across 1900 feet away from T2 laboratories and thus causing
damages to its surrounding environment. 16 business premises were surveyed in this report and
found that buildings located approximately 600 ft. away from T2 laboratories suffer irreparable
damages. Moreover, structures such as rail road and Faye road were also damaged due to debris of
explosion. 167 employees from different business premises were present at the time of incident
with 32 of them sustained minor injuries while four T2 employees succumbed to their death due to
close proximity with the reactor. Hence, this explosion had brought about both physical and human
consequences.
The root cause of the runaway reaction was identified to be due to lack of knowledge of a second
and more energetic exothermic reaction during the design of the MCMT production line. Because of
the ignorance, there were no redundancies in the design of the reactor, which has led to an
inefficient water cooling system and an ineffective pressure relief system. The failure of the water
cooling system has triggered the runaway reaction and the excessive temperature and pressure
generated from the reaction caused the reactor to explode.
The reactor explosion can be explained by the fast fracture failure mechanism. As pressure increase
within the reactor, the total elastic energy increases. When this reaches a critical limit where the
internal perforations of the wall become unstable and grow instantaneously, the energy of the
system will be released abruptly, causing a massive explosion. Therefore, when designing high
pressure reactors, it is very important to take note of the critical stress of the system and implement
appropriate stress relief measures.
In order to prevent future incident, recommendations are made. The most important part is to do
OH&S checks on working place. OH&S is essential for employer to prevent potential incident from
occurring and to be able to response to emergency situations. The next important thing is the
knowledge on hazard; therefore hazard education is important for each tester/employee. Finally,
chemical testings are to prevent the improper balancing on scaling up after lab test.
5. Page | 4
1.0 Introduction
T2 Laboratories Inc. is a chemical processing facility that specialized in the design and manufacture
of chemicals primarily for gasoline additives. It is a small privately owned chemical manufacturing
plant located in the largest city in the state of Florida, Jacksonville that began operations in 1996. A
chemical engineer and a chemist founded T2 as a solvent blending business. From 1996 to 2001, T2
operated from a warehouse located in a mixed-used industrial and residential area in downtown
Jacksonville. In 2001, T2 expanded their business by leasing a 5 acre site in north of Jacksonville to
construct a MCMT process line. In January 2004, T2 began full scale production of MCMT and by
December 2007, MCMT production was the primary business operation (T2 Laboratories Inc.
Runaway Reaction 2009).
Since 1947 MCMT has been commonly used as a supplement to increase the octane rating in fuels. It
is also used as a lubricant to prevent automotive engine valve seat recession. However, this fuel
additive is a combustible liquid and is very toxic by inhalation or skin contact. Both the National
Institute for Occupational Safety and Health (NIOSH) and Occupational Safety and Health
Administration (OSHA) set exposure limits for MCMT whereas the Environment Protection Agency
(EPA) designates MCMT as extremely hazardous substances despite its quick decomposition
characteristics under exposure to sunlight (T2 Laboratories Inc. Runaway Reaction 2009).
The MCMT plant consists of extensive pipe networks which include the coolant line, product line,
heating line and the drainage line. However, primary reactions occur in the jacketed chemical batch
reactor which is considered one of the main components in the MCMT process line. A chemical
batch reactor is widely used in the process industries for a variety of process operations such as
solids dissolution, product mixing, chemical reactions, batch distillation etc. A typical batch reactor
consists of a tank with an agitator and integral cooling system or heating system (Batch Reactors
n.d.).
The production of MCMT could be simplified into three steps which are the metalation step,
substitution step and finally the carbonylation step. The first step in the MCMT manufacturing
process involves reaction of liquid chemicals with sodium metals in the chemical batch reactor
(metalation process). The reactants are heated to a temperature of 3000
F while being mixed with an
agitator. This exothermic reaction releases heat energy into the batch reactor and at the same time
produces hydrogen gas as a by-product which is vented into the atmosphere. In normal operational
conditions, the temperature of the reactants is allowed to rise to 3600
F before the operator initiates
the cooling system. The coolant used in this system is domestic water which is pumped through the
cooling lines into the jacket of the batch reactor. When the coolant boils, it will absorb the heat and
then be released as steam into the atmosphere. The cooling system is controlled by an operator
using a computerised control system to maintain the batch reactor below 3600
F (T2 Laboratories Inc.
Runaway Reaction 2009).
On December 19, 2007, T2 laboratories were producing its 175th batch of methylcyclopentadienyl
manganese tricarbonyl (MCMT) in the 2500 gallon chemical batch reactor. At 1.23pm, the process
operator directed an outside operator to call the two owners, who were off site to report a cooling
problem and request they return. The operator initiated the cooling system at 3600
F to cool the
6. Page | 5
reactor as usual however the cooling system appears to be ineffective. At this point, the
temperature and pressure inside the batch reactor continued to rise uncontrollably.
A few minutes after the call, the two owners returned to the manufacturing plant. While one of the
owners searched for the plant mechanic, the other went to the control room to assist the operator.
The owner in the control room was concerned about a possible fire, he warned employees to move
away from the reactor.
The pressure inside the batch reactor caused the rupture disc in the pressure relief system to burst
at 400lbs/in2
as designed. However, the pressure inside the batch reactor continued rising exceeding
600psig, which is the maximum allowable working pressure of the batch reactor. At about 1.33pm,
the batch reactor gave into the pressure and erupted. The blast was heard from miles away and the
plant continued to burn in flames as the explosion destroyed assets in surrounding factories. The
blast damaged buildings about 1500ft away causing debris to be flown up to 1 mile away.
Unfortunately, 4 people were killed in this blast including the co-owner of the company.
Furthermore, 32 people were injured and taken to the hospital. The blast is said to have an impact
equivalent to 1400 pounds of TNT explosives.
The U.S. Chemical Safety and Hazard Investigation Board (CSB) carried out extensive investigations
and identified the root cause as T2 not recognizing the runaway reaction hazard associated with the
MCMT it was producing. A chemical runaway reaction refers to a situation where an increase in
temperature changes the conditions in a way that causes a further increase in temperature, often
leading to a destructive result (HSE 2007). The reaction consists of a second undesired exothermic
reaction that started at a higher temperature. During the 5th
batch of MCMT production, drastic
increase in temperature was observed but was ignored. Even worse, the owners intentionally
increased the batch size by one-third when customer requests increased.
Other contributing causes of the disaster are that the cooling system employed by T2 was
susceptible to single-point failures due to lack of design redundancy. The designers did not include
back-up cooling systems in case of a breakdown. Furthermore, the workers and owners at T2 did not
practice preventive maintenance on the process plant. This is proven on at least one occasion in
2006, the reactor drain valve had failed during operations and required repair.
In addition, the MCMT reactor pressure relief system was incapable of relieving the pressure from a
runway reaction. The CSB determined that it is unlikely for the pressure relief system set at 400Psig
to release the pressure in time once the second exothermic reaction started. However, if T2 had set
the pressure release valve to rupture at 75Psig, the disaster would have been avoided completely.
A combination of design errors and negligence has resulted in the loss of human lives. Furthermore,
this incident led to financial, environmental and legal consequences.
This report starts with failure analysis, which includes Fault tree analysis(FTA) and Failure Mode and
Effects Analysis (FMEA), followed by the theory behind the explosion disaster. Next, the report
outlines the consequences of the disaster, which includes the physical damages on the surrounding
environment and the casualties involved. The report also discusses the lessons learnt from this
incident and the recommendations to avoid future similar disasters.
7. Page | 6
2.0 Failure Analysis
2.1 Sequence of events
Date and Time Personnel Event
December 18, 2007
Evening Night shift operator Prepared reactor for new MCMT batch
December 19, 2007
7:30 am Day shift operator Began manufacturing process for Batch 175
from control room
11:00 am Day shift operator Batch heated to initiate chemical reaction
Monitored the temperature and pressure
1:23 pm Day shift operator Noticed cooling problem
Asked outside operator to call owners
1:26 pm Day shift operator,
Owner/chemical engineer
Diagnose problem in control room
Owner/chemist Searched for plant mechanic
1:29 pm Owner/chemical engineer Went to the reactor and mentioned employees
to get away
1:31 pm Owner/chemical engineer Returned to control room
1:33 pm Reactor’s pressure relief system cannot control
runaway reaction
Eyewitnesses Saw venting from the reactor and heard loud
sound then the reactor exploded
Table 1: Sequence of events
2.2 Failure Modes and Effects (Criticality) Analysis (FMECA) and Fault Tree Analysis (FTA)
Component or
activity
Failure Mode Severity of
Failure (C)
Frequency (F) Mitigation (M) Risk Measure
(CFM)
Water supply
valve or water
drain valve
Fails to open
or close
Insufficient
coolant flow
rate into the
reactor jacket,
C = 8
0.3 per year,
F = 6.5
Flow of
coolant
through a
bypass valve,
M = 1
52
Pneumatic
system
Does not work
or react
Valve does not
operate
causing no
coolant flow,
C = 9
0.3 per year,
F= 6.5
No regular
preventive
maintenance,
M = 8
468
Water supply
piping
Blockage due
to mineral
scale built up
Insufficient
cooling
causing
pressure built
up in reactor,
C = 10
0.1 per year,
F = 6
Low
probability
avoidance of
mineral scale
build up,
M = 9
540
Temperature
indicator
Faulty
Incorrect
temperature
reading of the
reactor,
C = 9
0.01 per year,
F = 5
No backup
temperature
reader,
M = 10
450
Table 2: FMECA of T2 Explosion
9. Page |7
2.3 Root cause of failure
According to the incident analysis conducted by the U.S. Chemical Safety and Hazard Investigation
Board (CSB), there were six possible causes for the runaway reaction to occur. These six causes were:
i. Cross-contamination of the reactor
ii. Contamination of raw materials
iii. Wrong concentration of raw materials
iv. Local concentration of chemical within the reactor
v. Application of excessive heat
vi. Unidentified chemical reaction
While scenarios (i) to (v) could be the culprit behind the runaway reaction, they were determined to
be highly unlikely to have happened (T2 Laboratories Inc. Runaway Reaction 2009).
In an interview with the T2 owner/chemist, he mentioned that cross-contamination of the reactor
had previously occurred and the only consequences were low yields or batch polymerisation. The
possibility of contamination of raw materials was similarly ruled out as the raw materials used on the
day of the incident came from the same shipments that had been used in previous successful
batches.
Based on the reaction chemistry, the accelerated reaction rate that caused the runaway reaction
could only have occurred if there was an increase in the amount of sodium loaded into the reactor.
Since sodium was hand-loaded by operators in fixed batches, wrong concentration of raw materials
was unlikely. On the other hand, varying local concentration within the reactor would reduce rather
than accelerate reaction rate because maximum reaction rate can only be achieved with uniform
distribution of raw materials.
In the case of heat application, hot oil system was used and calculations have shown that the cooling
system had the capacity of 10 times greater than the maximum capacity of the hot oil system (T2
Laboratories Inc. Runaway Reaction 2009). If the heating had continued beyond 300o
F (148.9o
C), the
cooling system would have removed the excess heat easily.
With most of the scenarios being ruled out, the only credible scenario to have caused the incident
was lack of knowledge in a chemical reaction previously unidentified when designing the MCMT
production line. According to the results of the laboratory testing conducted on the batch recipe
used by T2 on the day of the incident, the standard T2 chemical recipe, without sufficient cooling,
would trigger a second and more energetic exothermic reaction when the temperature exceeded
390o
F (198.9o
C) (T2 Laboratories Inc. Runaway Reaction 2009). This second exothermic reaction was
capable of producing extreme temperature and pressure. However, the T2 owner/chemist reported
that he have no knowledge on the second exothermic reaction as the laboratory testing that he had
conducted never exceeded 380o
F (193o
C). Since the owner/chemist did not investigate the reaction’s
behaviour at higher temperatures, he did not observe evidence of exothermic runaway potential,
thus allowing the second exothermic reaction to occur and caused the reactor explosion on
December 19, 2007.
Insufficient cooling, as reported by the process operator stating that there was a cooling problem
shortly before the explosion, had contributed to the triggering of the runaway chemical reaction.
10. Page | 9
When investigators looked into the design of the reactor, as shown in Figure 2 below, they found out
that the cooling water system lacked design redundancy, making it susceptible to single-point
failures including
Failures of water supply valve or water drain valve
Failure of the pneumatic system that was used to operate the water valves
Blockage or partial blockage in the water supply piping
Faulty temperature indication
Mineral scale build-up in the cooling system
Figure 2: Possible failure components of the reactor and ductile tearing of perforations in material (Image
Courtesy of T2 Laboratories Inc. Runaway Reaction 2009)
As mentioned, without sufficient cooling, the T2 chemical recipe was capable of producing extreme
temperature and pressure. Therefore, failure in any of the components in the water cooling system
would have caused the heat removal cycle to malfunction. Formation of mineral scale inside the
cooling jacket could also interfere with the heat removal capacity of the cooling water system as
loose scale could have blocked the water piping. All of these would have enabled the temperature
and pressure to build up in the reactor and finally caused the violent reactor failure to occur.
11. Page | 10
Unfortunately, T2 took no initiative to contain this hazard as interviews with employees have shown
that T2 would usually ran cooling system components to failure and did not perform routine
preventive maintenance. There were even occasions since 2006 where the reactor cooling drain
valve had failed during operations and required repair. Subsequently, there was also no backup
water supply to provide cooling water should the main water supply be cut off due to unforeseen
circumstances. Although a control system malfunction or operator error might also have led to the
insufficient reactor cooling problem, there was no evidence to indicate that either of these have
occurred.
Another contributing cause to the reactor explosion was the ineffective pressure relief system. T2
sized the pressure relief devices at 400psig, which was based on anticipated normal operations,
namely the maximum expected hydrogen gas generation during normal operation, without
considering potential emergency conditions. If T2 had set the pressure relief devices to 75psig, the
runaway reaction would have been relieved during the first exothermic reaction, preventing the
triggering of the second exothermic reaction.
2.4 Theory behind physical failure mechanism
As mentioned in the previous subsection, due to ineffective cooling and pressure relief system, the
temperature and pressure build-up in the reactor ultimately lead to a catastrophic explosion. The
failure mechanism of the explosion is most likely overloading, or more specifically failure by fast
fracture, which is the instantaneous growth of existing perforations in the material as they abruptly
become unstable.
2.4.1 Explosion by fast fracture
In this context, as the pressure in the reactor escalate dramatically due to the chemical reaction, the
total amount of elastic energy in the system increases. As the pressure eventually build-up to the
critical pressure for fast fracture, the existing perforations in the material that made up the reactor
walls will become unstable and grow suddenly, causing explosion (Ashby & Jones 2002). Therefore, it
is of utmost importance that all pressure vessel designers take into account the critical stress of the
system.
The critical stress of a system can be derived from a simple energy balance equation. As shown in
the equation below, for fast fracture to occur, the work done by loads must be more than the
change in elastic energy and the energy absorbed at the crack tip, where is the toughness of the
material. The toughness for steels range from 10kJm-2
to 103
kJm-2
(Ashby & Jones 2002).
where = Work done by external loads
= Change in elastic energy
= Thickness of material
= Change in crack/flaw size
12. Page | 11
From the above relationship, and by considering a fixed displacement fast fracture, the fast fracture
condition for engineering structures can be obtained.
√
where = Fracture toughness, √
= Stress subjected/critical stress
= Crack/flaw size
= Numerical correction factor
In the context of T2 lab reactor explosion, an estimation of the material perforation size, , and the
fracture toughness, , should be readily available from the reactor designer. Since the existing
flaws of the reactor must be microscopically small, the numerical correction factor, , can be
assumed to be 1. Finally, based on the equation shown above, the critical stress, , can then be
easily calculated. The maximum allowable pressure for the system can then be worked out from this
value. In the accident, because the pressure exceeded this critical value, it caused an explosion.
2.4.2 Micromechanisms of fast fracture
Before fast fracture occurs, the internal cracks or perforations start to propagate due to stress
localisation around the crack tip. At these stress concentrated areas, the localised stresses will reach
the yield stress of the material quicker than the average stress applied. As shown in the equation
below, the closer it is to the crack tip, the higher the stress. This also make the crack behaves as if it
is longer, where this effective crack tip in the plastic region is known as the notional crack tip
(Janssen, Zuidema & Wanhill 2004).
( )
where = Distance from the crack tip
When the material starts to tear at these areas, plastic flow occurs around the small inclusions of
chemical compounds that are commonly present in most metals. The crack will grow due to the
coalescence of voids in the plastic region near the crack tip. This mechanism is known as the ductile
tearing and can be illustrated in the Figure 2 above (Ashby & Jones 2002).
In most general situations, the plastic flow near the crack tip will turn the originally sharp tip into a
blunt tip, thus reducing the stress concentration and eventually stopping the crack propagation
(Ashby & Jones 2002). In the T2 laboratory accident, the pressure and stress involved are so great
that it is enough to create instantaneous crack propagation, leading to a rapid release of the stored
energy of the whole system, causing a massive explosion.
13. Page | 12
3.0 Consequences
Due to the massive explosion with magnitude that sums up to approximately 1400lb of
Trinitrotoluene (TNT) (T2 Laboratories Explosion Damage Assessment 2010), its damages impact
manage to extends up to 1900 feet surrounding the T2 laboratories (T2 Laboratories Inc. Runaway
Reaction 2009).
Figure 3: Map of T2 laboratories and its surrounding within 1900ft (Image courtesy of T2 Laboratories
Explosion Damage Assessment 2010)
Analysis on the damages was conducted in this project and can be categorised into physical, human
and financial damages. Damages on buildings and structures are part of the physical consequences
caused by the explosion. ABS has conducted a qualitative observation that surveys all buildings
involved in the explosion by using two types of approaches known as the Explosive Risk and
Structural Damage Assessment Code (ERASDAC) and SDOF Blast Effect Design Spreadsheet (SBEDS)
(T2 Laboratories Explosion Damage Assessment 2010). Both approaches describe buildings damages
Faye Road
Rail Road
T2 LaboratoriesWall Street Trailers
14. Page | 13
level as given in table 3 and 4 respectively. Table 5 summarizes the result of damages level on some
of buildings surrounding T2 laboratories using both approaches.
Building Damages Level Damage Description
1 Onset of visible damage to reflected wall of building.
2A Reflected wall components sustain permanent damage requiring
replacement, other walls and roof have visible damage that is generally
repairable.
2B Reflected wall components are collapsed or very severely damaged. Other
walls and roof have permanent damage requiring replacement.
C Reflected wall has collapsed. Other walls and roof have substantial plastic
deformation that may be approaching incipient collapse.
D Complete failure of the building roof and substantial area of walls.
Table 3: Damage level description using ERASDAC
Building Damage Level Damage Description
Superficial No permanent deformations. The facility is immediately operable.
Repairable Space in and around damaged area can be used and is fully functional
after clean-ups and repairs.
Unrepairable Progressive collapse will not occur. Space in and around the damaged
area is unusable.
Heavy Onset of structural collapse. Progressive collapse is unlikely. Space in and
around damaged area is unusable.
Severe Progressive collapse likely. Space in and around damaged area is
unusable.
Table 4: Damage level description using SBEDS
Buildings
Distance from T2
(feet)
Damage Level
ERASDAC SBEDS
Stover Sales 970 1 Superficial
Prezine 570 2A Unrepairable
MastHead 550 2A Unrepairable
PBM Construction 720 2A Repairable
Refractory Repair Service 1005 2A Repairable
Wall Street Trailers 250 2B Heavy
Tri – State Contractors 300 3 Heavy
Cogburn Brothers 895 2A Repairable
Wilkinson Steel 660 1 Superficial
School Bus Depot 1467 1 Superficial
Maccurrah Golf Construction 880 2A Repairable
Personal Residence (Trailer) 1040 1 Superficial
Unknown name 1450 1 Superficial
Truck Lease Services 1660 1 Superficial
Arlington Heavy Hauling 833 2A Some Unrepairable
Petticoat Construction Company 1447 1 Superficial
Table 5: Summary of some buildings damaged level
15. Page | 14
As a result of this explosion, other businesses surrounding T2 have been greatly affected. For
example, Wall Street Trailers, a trucking company which had trailer as their office located 250ft away
from T2 laboratories, was completely destroyed by the explosion suffering heavy damages as shown
in Figure 3. Fortunately, no employees were present during the time of incident. Besides that,
structures such as a rail road were pushed out of place caused by the impact of collision with a
2000lb section of the 3 inch thick reactor head (Figure 3). A 4 inch diameter agitator shaft from the
reactor had caused crack damage on Faye Road situated 350 ft. away from T2 (Figure 3). All these
were caused by force of the blast that propels debris from T2 to all directions (T2 Laboratories Inc.
Runaway Reaction 2009).
A total of 36 victims from T2 laboratories and its surrounding businesses were involved in this
disastrous incident. Unfortunately, four T2 employees were killed instantly by the explosion due to
their very close standoff distance from the reactor during the time of incident. Meanwhile, there are
five other T2 employees (one of them is a truck driver that delivers mineral spirit to T2) that escaped
the fatality of the explosion with only one critically injured while the rest attained minor injuries. The
remaining 28 victims are employees from businesses surrounding T2 laboratories as those listed in
Figure 4. Injuries reported from these employees were either lacerations or contusions, hearing loss,
or thrown by the force of the explosion blast that travelled 1900 feet wide (T2 Laboratories Inc.
Runaway Reaction 2009). Figure 4 present a summary of injury statistics of victims from T2
laboratories and its surrounding businesses; there were a total of 167 employees from different
businesses present during the time of incident.
Figure 4: T2 Laboratories Explosion Injury Statistics
As seen from the consequences from this incident, an explosion in a chemical plant is highly
dangerous as its impact could travel a wide distance affecting also the surrounding environment; this
may bring about a large death and injury tolls. Moreover, it could also lead to daily operation failure
of other businesses which may lead to financial losses in a company. Therefore, precaution steps and
0
5
10
15
20
25
30
Numberofemployees
Business Name
Death
Minor injuries
No injuries
16. Page | 15
safety work operation should always be prioritised and practiced in a chemical plant that produces
explosive chemical.
4.0 Recommendation
The T2 Laboratories explosion occurred due to many failures of components that had led to fatal
catastrophe. In this section recommendations are made in order to prevent such event to take place
in the future.
a) Chemical Testing
One of the reasons that these incidents occur is due to underestimation of the T2 employee.
It is stated that MCMT production has little references that can be relied on hence
laboratory testing is required. However T2 had only done test on 1 litre scale of reactor and
since the test run smoothly, the tester did not perform full scale analysis on the full scale
reactor. Cooling requirements in one litre test did not indicate the correct amount coolant
required for full scale reactor to prevent exothermic reaction to occur. Hence it is
recommended to perform a full scale analysis before proceeding in production of first batch
of MCMT, as stated in Designing and Operating Safe chemical Reaction Processes (HSE 2000),
it is important to properly scale-up design process equipment and the potential for incidents
to occur in full scale processes that have appeared uneventful in testing.
b) Process Hazard Analysis
In chemical reaction process it is required to perform Process hazard analysis. It is done in
order to establish operating limits and identify operating strategies to prevent run away
reactions. Analysis on reactor systems can help to determine the potential process
deviations and equipment malfunctions, including agitator failure, loss of cooling,
contamination and mischarging feed stocks, all of which are common causes for runaway
reactions. One of process hazard analysis that can be performed is Hazard and operability
study (HAZOP) during the scale-up. By doing HAZOP it is likely to identify the Nature of
reaction and the limitations of the cooling and pressure relief systems.
c) Hazard education
The knowledge of understanding the hazard reactivity and process safety education is
important. Therefore it is highly recommended that all engineering degree include this
education inside the curriculum of the study. With this knowledge engineers will understand
how important to perform runaway reaction testing, address emergency relief, and identify
as well as evaluate the cause the process upsets. This will help to reduce the possibility of
the incidents to occur.
d) Occupational Health & safety
It is requirement in workplace that OH & S implemented by the employer, it is to create a
management program to prevent or to minimize the consequences of catastrophic releases
of hazardous chemicals. Some of the key elements in OH&S are conducting Process hazard
analysis, implementing and maintaining written operating procedures, set up periodic
operator training, and executing a management change program.
It is also required to do risk management planning to understand the chemicals that pose
significant hazards to surroundings if accidental releases occur. In risk management planning
17. Page | 16
report, it is required to include the response on emergency situation including worst case
and alternative release scenarios, as well as the plan to improve safety.
5.0 Significance of event
5.1 Comparison with similar events
T2 laboratories explosion was not the only disaster that occurred due to the failure of chemical
reactor. There were comparably similar events that occur in industries and plants all around the
world. In this section, similar incidents to T2 explosion will be stated and briefly discussed.
a) Morton International Inc. (April 8,1998)
This disaster has occurred In Paterson, New Jersey, The incident caused fire and explosion as
the consequences of runaway reaction. Nine employees were injured. It also caused the
release of chemicals into the community and damage to the plant (HSE 2007).
The runaway reaction was caused by the yellow 96 reaction, which accelerated beyond the
heat removal capability of the reactor; it causes a secondary runaway decomposition
reaction, causing an explosion that blew up the reactor hatch and released the reactor
contents. The initial runaway reaction is due to incapability of the cooling system of
controlling the exothermic reaction and there are no emergency shutdown program
installed.
The cooling failure is due to the inadequacy of Morton Inc. to evaluate and control the
Yellow 96 production process.
b) Concept Sciences Inc. (February 19, 1999)
Concept Sciences Inc. facility that has vessel containing hundreds of pounds of
hydroxylamine explodes. This explosion occurred near Allentown, Pennsylvania. The facility
was making the first batch of hydroxylamine; during the distillation process the piping and
the process tank decomposed, this was most likely due to high temperature and high
concentration. The disaster killed four employees and the manager of the adjacent business.
Four other people near the building were injured. The explosion also caused significant
damage to other buildings.
The company has developed the hydroxylamine through laboratory test, and set up the full
production facility in July 1998. The production parameters involved a high concentration of
hydroxylamine which could cause exothermic decomposition, forming explosive crystal. The
company did not evaluate the reactive hazards of the process during the production
development phase, determine the scale of the hazard, nor identify the control measures.
c) MFG Chemical Inc. (April 12, 2004)
MFG was producing its first batch of triallyl cyanurate (TAC). However, a runaway reaction
occurred and over pressurized the chemical reactor at the MFG plant. This incident caused
the release of toxic allyl alcohol to the environment. The toxic cloud hospitalised 154 people,
killed nearby vegetation and aquatic life.
It was later found out that MFG had not carefully researched the reactive hazards of the
process before scaling up from lab test to full scale production. The reaction test done by
18. Page | 17
MFG was designed to maximize yield and minimize production cause without involving
additional exothermic reaction into consideration, this reaction require extra cooling. MFG
had underestimated the removal capacity between the test batch and the full scale
production (HSE 2007).
d) Synthron (January 31, 2006)
In Morganton, North Carolina a disaster of vapour cloud explosion and fires killed one
worker, injured 14 people, and damaged structures in the nearby community. The source of
this explosion takes place in Synthron facility. This facility manufactured varieties of powder
coating and paint additives, the process done by polymerizing acrylic monomers in a reactor.
The background of the explosion is due to increase of order of slightly more additive than
the normal size recipe produced; hence the plan managers scale up the recipes to meet the
requirement. This caused more than doubled the rate of energy release in the reactor,
exceeding the cooling capacity of the reactor condenser, which led to runaway reaction. The
reactor over pressurised, solvent vapours vented from the reactor’s manway, flammable
cloud form inside the building and hence the vapour found the ignition source hence it
explodes.
Main cause of this catastrophe is due to failure of identifying the hazards associated with
this type of chemistry, additionally the process safety documentation is poorly arranged, the
recipes changed without further analysis, the safeguards to prevent the runaway reaction
does not exist.
5.2 Learning
There are several lessons that can be learnt from this tragedy. Most of the incidents background is
due to underestimation and carelessness of the employee in preparing the full scale reaction.
Firstly the chemical testing should have been done properly; it is crucial, before the start of doing
any process design, to investigate further the effect of scaling in process system reactor.
Underestimation of the effect of scaling must be avoided in the future. The chemical reaction may
act in different manner than the laboratory testing hence scaling effect investigation is crucial.
The other main concern that should have taken into account is the knowledge of hazard information
and analysis. This section need to be emphasized to the employer hence all the employee will
understand and be more responsible on the part that they are assigned and assured about the safety
of the process they are doing. Understanding the hazard will help the employee to perform analysis
on each of the dangerous process they are assigned to and hence reducing the potential of the
damage and able to take response on the emergency situation.
Finally it is needed to apply OH&S in workplace especially where dangerous chemical is involved. It is
compulsory for employer to make sure the safety of its employee and by applying the OH&S this can
be achieved.
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Conclusions
The 1400 pounds of TNT equivalent explosion at T2 laboratories on December 19, 2007 is considered
U.S.’s most severe industrial accident in nearly five years. The massive explosion and fire killed four
people, while leaving 28 people injured. The cause of the explosion was due to a system cooling
failure that presents insufficient cooling of the chemical batch reactor. Insufficient cooling of the
batch reactor caused an unwanted second exothermic reaction to occur causing high temperature
and pressure build up in the reactor which led to the explosion.
The failure of the cooling system was due to several reasons including blockages in pipes due to
mineral deposition, valve failure or pneumatic failure. However, the cooling system in the T2
laboratories process plant was not designed with redundancy. If a backup cooling system were to be
installed, the disaster could be avoided completely. Furthermore, staffs at T2 laboratories were not
train to perform preventive maintenance, and components in the process plant are allowed to
function until failure.
To prevent disasters such as this to occur again, national regulatory bodies which controls industrial
operations sectors should recommend more stringent rules for process plant designs. Chemical
testings should be carried out to ensure all possible reactions be recorded to account for them in the
design stage. In addition, process Hazard analysis of the entire process should be carried out to
ensure any possible hazards are eliminated or controlled. Furthermore, employers are responsible
for instilling good operation health and safety habits to create a safe working culture amongst
employees. In any industry, safety should be made the highest priority. A culture of preventive
maintenance should be practiced and employees and employers alike should solve any maintenance
issue despite the cost.
20. Page | 19
References
Ashby, M.F. & Jones, D.R.H. 2002, Engineering Materials 1: An Introduction to their Properties and
Applications, 2nd edn, Butterworth-Heinemann, Great Britain.
Janssen, M., Zuidema, J. & Wanhill, R. 2004, Fracture Mechanics, 2nd edn, Spon Press, Oxfordshire.
T2 Laboratories Inc. Runaway Reaction 2009, US Chemical Safety and Hazard Investigation Board,
Washington DC.
T2 Laboratories Explosion Damage Assessment 2010, ABS Consulting, San Antonio.
Health and Safety Executive (HSE) 2007, Health and Safety Executive, Sudbury, Suffolk, viewed 28
August 2012, <http://www.hse.gov.uk/pubns/indg254.htm>
Batch Reactors n.d., University of Michigan, Michigan, viewed 27 August 2012,
<http://www.engin.umich.edu/~cre/asyLearn/bits/batch/index.htm>