Incompatible Chemicals: Explosion at AB Specialty Silicones

Summary

On May 3, 2019, a catastrophic explosion at AB Specialty Silicones in Illinois killed four workers due to the mixing of incompatible chemicals, producing flammable hydrogen gas. The Chemical Safety Board's investigation revealed safety lapses, including the lack of a hazard analysis program and inadequate safety management systems. The incident underscores the critical need for companies to implement robust safety measures, including proper chemical storage, gas detection systems, and effective emergency training, to prevent such tragedies.

Takeaways

• 🔍 On May 3, 2019, a catastrophic explosion at AB Specialty Silicones in Waukegan, Illinois, resulted from the accidental mixing of incompatible chemicals, causing the release of flammable hydrogen gas.
• 👷‍♂️ The incident led to the tragic loss of four workers' lives, highlighting the severe consequences of reactive chemical mishandling.
• 🚨 The Chemical Safety Board (CSB) investigation revealed that the company lacked basic safety management systems to control reactive chemical hazards.
• 📚 The absence of a written procedure to segregate incompatible chemicals and the use of nearly identical containers contributed to the confusion and subsequent disaster.
• 🏭 The design flaws in the batch equipment and ventilation system exacerbated the situation, allowing the hydrogen gas to accumulate and ignite within the production building.
• 🔬 The CSB emphasized the importance of having a robust hazard analysis program to identify and mitigate potential safety hazards in chemical processes.
• 🛠️ The company's inadequate response to a previous incident in 2014, which also involved a drum explosion, indicated a weak safety culture and lack of effective safety management systems.
• 📈 The CSB recommended that AB Specialty develop hazardous gas detection and alarm programs, which could have alerted workers to the hydrogen gas danger and prompted a timely evacuation.
• 📋 Regulatory gaps were identified, with the CSB calling on OSHA and the EPA to update their standards to include better coverage of reactive chemical hazards.
• 🌐 The incident underscores the need for comprehensive safety measures, effective training, and regulatory oversight to protect workers, property, and the environment from the risks associated with reactive chemicals.

Q & A

What was the date and location of the explosion at AB Specialty Silicones?

The explosion occurred on May 3, 2019, at the AB Specialty Silicones facility in Waukegan, Illinois.

What was the cause of the explosion at AB Specialty Silicones?

The explosion was caused by the mixing of two incompatible chemicals, which reacted to produce flammable hydrogen gas that ignited.

How many workers were killed in the AB Specialty Silicones explosion?

Four workers were killed in the explosion.

What product was being produced at the time of the explosion?

The product being produced was an emulsion known as Andisil EM 652, used as a waterproofing agent.

What was the role of the batch ticket in the manufacturing process of Andisil EM 652?

The batch ticket detailed the operation steps for manufacturing Andisil EM 652, guiding the operators in staging and mixing the chemical ingredients.

Why was potassium hydroxide added to the first batch of EM 652?

Potassium hydroxide was added to the first batch of EM 652 because the pH of the product samples was too low, as determined by the Quality Control department.

What mistake led to the release of flammable hydrogen gas?

A second shift operator likely misidentified the drums containing 10% potassium hydroxide for XL-10 and incorrectly added potassium hydroxide to the tank, leading to a reaction that produced flammable hydrogen gas.

What safety issues were identified by the Chemical Safety Board (CSB) as contributing factors to the explosion?

The CSB identified several safety issues, including the lack of written procedures for separating incompatible chemicals, the design of the batch equipment and ventilation system, and the absence of a hydrogen gas detection and alarm system.

Why was the explosion particularly severe?

The explosion was severe due to the open hatch type lid on the emulsion process tank, which allowed hydrogen gas to release directly into the production building, and the building's ventilation system, which may have helped distribute the hydrogen gas, creating a large explosive gas cloud.

What recommendations did the CSB make to AB Specialty Silicones to improve safety?

The CSB recommended that AB Specialty Silicones develop hazardous gas detection and alarm programs, ensure proper installation and maintenance of such systems, and improve emergency preparedness training for workers.

What regulatory gaps were highlighted by the CSB in relation to reactive chemical hazards?

The CSB highlighted that AB Specialty's chemicals, despite being capable of hazardous reactions, were not covered under OSHA's Process Safety Management Standard or the EPA's Risk Management Plan Rule, leading to a lack of required baseline process safety management system elements.