Runaway: Explosion at T2 Laboratories

Summary

On December 19, 2007, T2 Laboratories in Jacksonville, Florida, experienced a catastrophic explosion due to a runaway chemical reaction in a reactor producing MCMT, a gasoline additive. The blast resulted in fatalities, injuries, and significant property damage. The incident highlighted the importance of understanding and managing reactive chemical hazards, effective emergency pressure relief systems, and the need for comprehensive training in chemical engineering to prevent such tragedies.

Takeaways

• 🔥 On December 19, 2007, a catastrophic explosion and fire at T2 Laboratories in Jacksonville, Florida, resulted in fatalities and injuries, highlighting the dangers of runaway chemical reactions.
• 🏭 T2 Laboratories produced methylcyclopentadienyl manganese tricarbonyl (MCMT), a gasoline additive, using a 2500-gallon reactor with a computerized control system.
• ⚠️ The explosion was caused by a malfunctioning cooling system during an exothermic reaction, leading to a temperature and pressure spike in the reactor.
• 👨‍🔬 The company's co-owners were killed in the incident, emphasizing the severity of the consequences of not managing chemical processes correctly.
• 🏢 The blast had a significant impact, damaging buildings over 1500 feet away and causing debris to travel up to a mile, showcasing the power of the explosion.
• 📊 A CSB study identified 167 serious accidents due to uncontrolled chemical reactions between 1980 and 2001, resulting in 108 deaths and substantial property damage.
• 🔬 T2 scaled up their MCMT process directly from a one-liter reactor to full production without addressing the increased challenges in cooling and controlling the reaction.
• 🚨 The company's lack of a comprehensive cooling system and absence of a backup plan for malfunctions contributed to the disaster.
• 📚 The CSB emphasized the importance of education and awareness in recognizing and controlling reactive hazards, which was lacking in T2's operations.
• 🛠️ To prevent such accidents, the CSB recommended that companies implement emergency pressure relief systems, design safeguards, effective operating procedures, and training programs.

Q & A

What event is described in the video script?

The video script describes a powerful explosion and fire that occurred at T2 Laboratories in Jacksonville, Florida on December 19, 2007.

What was the cause of the explosion at T2 Laboratories?

The explosion was caused by a runaway chemical reaction in the reactor due to a malfunctioning cooling system, leading to a loss of temperature control.

What chemical was being produced at T2 Laboratories when the explosion occurred?

T2 Laboratories was producing methylcyclopentadienyl manganese tricarbonyl (MCMT), a gasoline additive.

What were the consequences of the explosion in terms of fatalities and injuries?

The explosion resulted in the death of the co-owner and the operator in the control room, and two other operators died from flying debris. Additionally, 32 other people were injured, including 28 at nearby businesses.

How far did the blast impact reach?

The blast damaged buildings over 1500 feet away and debris was found up to a mile from the explosion site.

What was the scale-up process like for T2 Laboratories' MCMT production?

T2 Laboratories developed its MCMT process using a one-liter reactor and then scaled up directly to a full production volume in a 2500-gallon reactor without a gradual scale-up.

What safety issues were identified in the company's handling of the MCMT production process?

T2 Laboratories had only a simple cooling system without a backup, and they did not fully investigate causes of temperature control issues during production runs. The company also lacked proper training on reactive hazards.

What recommendations were made by the CSB to prevent similar accidents in the future?

The CSB recommended that companies identify and evaluate reactive hazards, implement emergency pressure relief systems and design safeguards, develop effective operating procedures and training programs, and plan for possible accidents including evacuation drills and emergency response exercises.

What was the role of education and awareness in the context of the T2 Laboratories accident?

Education and awareness were highlighted as crucial in understanding and managing reactive chemistry hazards. The CSB noted that many incidents occur due to a lack of awareness among those operating the processes about the existence and potential consequences of reactive hazards.

What was the significance of the study completed by the CSB in 2002 regarding reactive chemical hazards?

The CSB's 2002 study identified 167 serious accidents involving uncontrolled chemical reactions between 1980 and 2001, causing 108 deaths and significant property damage, emphasizing the need for better control and understanding of reactive chemical hazards.

Outlines

00:00

💥 T2 Laboratories Explosion: A Case of Runaway Chemical Reaction

On December 19, 2007, a devastating explosion at T2 Laboratories in Jacksonville, Florida, resulted in fatalities and injuries among workers, and caused extensive damage to the facility and surrounding businesses. The incident, which was one of several investigated by the Chemical Safety Board (CSB), was caused by a runaway chemical reaction during the production of methylcyclopentadienyl manganese tricarbonyl (MCMT), a gasoline additive. The process involved mixing chemicals in a 2500-gallon reactor, which was controlled by a computerized system. A malfunction in the cooling system led to a rapid increase in temperature and pressure, culminating in an explosion equivalent to 1400 pounds of TNT. The blast had a significant impact, damaging buildings over 1500 feet away and causing debris to travel up to a mile. The video highlights the importance of understanding and managing reactive chemical hazards, including the need for proper emergency pressure relief systems and effective operating procedures.

05:03

📚 Preventing Reactive Chemical Accidents: Lessons from T2 Laboratories

The CSB's study on reactive chemical hazards, which identified 167 serious accidents between 1980 and 2001, underscores the need for companies to thoroughly evaluate and manage such hazards. T2 Laboratories' incident highlights the risks of scaling up chemical processes without adequate safety measures. The company's failure to address previous temperature control issues and reliance on a single, inadequate cooling system contributed to the disaster. The video emphasizes the importance of education and awareness in recognizing and controlling reactive hazards, suggesting that industry practices and chemical engineering curricula should include training on this topic. It also points to resources available for managing reactive hazards, such as publications from the Center for Chemical Process Safety and the Design Institute for Emergency Relief Systems. The CSB's recommendations aim to improve industry practices and prevent future tragedies.

Keywords

💡Explosion

An explosion is a rapid expansion of gases in a confined space, resulting in a release of energy that can cause damage and destruction. In the context of the video, the explosion at T2 Laboratories was a catastrophic event that resulted in fatalities, injuries, and significant property damage. The script describes the explosion as being equivalent to about 1400 pounds of TNT, indicating the scale of the disaster.

💡Chemical Reaction

A chemical reaction involves a change in the arrangement of atoms to form new substances. The video discusses 'runaway chemical reactions' which are uncontrolled chemical reactions that can lead to dangerous situations like explosions. The accident at T2 Laboratories was caused by such a reaction, where the temperature and pressure inside the reactor rose uncontrollably.

💡Methylcyclopentadienyl Manganese Tricarbonyl (MCMTC)

MCMTC is a chemical compound mentioned in the script as the product being manufactured at T2 Laboratories. It is used as a gasoline additive. The process of producing MCMTC involved a series of chemical reactions, and the video highlights the dangers of scaling up production without proper safety measures, which was a contributing factor to the accident.

💡Exothermic Reaction

An exothermic reaction is a chemical reaction that releases heat. The script explains that the reaction in the reactor at T2 Laboratories was exothermic, meaning it produced heat as a byproduct. This heat had to be carefully managed to prevent the reaction from becoming uncontrollable, which is what ultimately happened, leading to the explosion.

💡Cooling System

A cooling system is designed to remove excess heat from a process to maintain safe operating temperatures. In the video, the failure of the cooling system at T2 Laboratories is identified as a key factor in the accident. The script describes how the cooling system likely malfunctioned, leading to a rise in temperature and pressure that could not be controlled.

💡Runaway Reaction

A runaway reaction is a chemical reaction that accelerates and becomes uncontrollable, often due to a lack of effective heat removal. The video uses the term to describe the situation at T2 Laboratories, where the reaction inside the reactor escalated rapidly, leading to an explosion. The term is crucial for understanding the severity of the incident.

💡Pressure Relief System

A pressure relief system is a safety device designed to release pressure from a system to prevent explosions or equipment failure. The video suggests that the lack of an effective pressure relief system at T2 Laboratories contributed to the severity of the explosion. It is highlighted as a necessary safety measure to prevent similar accidents.

💡Reactive Hazards

Reactive hazards refer to the potential for chemicals to undergo uncontrolled reactions that can lead to accidents. The video emphasizes the importance of understanding and managing reactive hazards in chemical processes. The accident at T2 Laboratories is presented as a case study to illustrate the consequences of not adequately addressing reactive hazards.

💡Chemical Engineering

Chemical engineering is the application of science and engineering principles to the design, construction, and operation of processes that involve chemical reactions. The video notes that the owners of T2 Laboratories had undergraduate degrees in chemistry and chemical engineering but lacked specific training in recognizing and controlling reactive hazards, underscoring the need for comprehensive education in the field.

💡Safety Measures

Safety measures are precautions taken to prevent accidents and ensure the well-being of people and the environment. The video discusses various safety measures that should be in place, such as proper training, emergency pressure relief systems, and effective operating procedures. The lack of these measures at T2 Laboratories is highlighted as a contributing factor to the accident.

💡Education and Awareness

Education and awareness refer to the knowledge and understanding necessary to recognize and manage potential hazards. The video concludes by emphasizing the importance of education and awareness in preventing accidents like the one at T2 Laboratories. It suggests that improved industry practices and increased education will help prevent such tragedies.

Highlights

On December 19, 2007, a catastrophic explosion and fire occurred at T2 Laboratories in Jacksonville, Florida.

The blast killed and injured workers, destroyed T2 Laboratories, and damaged four nearby businesses.

The explosion was caused by a runaway chemical reaction, a common cause of accidents investigated by the CSB.

T2 Laboratories produced a gasoline additive called MCMT in a 2500-gallon reactor.

The process involved mixing liquid chemicals and sodium metal, which produced hydrogen.

Operators controlled the exothermic reaction with a computerized system and a cooling jacket.

On the day of the accident, the cooling system likely malfunctioned, leading to a runaway reaction.

The explosion was equivalent to about 1400 pounds of TNT, damaging buildings over 1500 feet away.

The co-owner and the operator in the control room were killed, and two others died from flying debris.

Thirty-two other people were injured, including 28 at nearby businesses.

The CSB's study on reactive chemical hazards identified 167 serious accidents between 1980 and 2001.

T2 developed its MCMT process without scaling up gradually, which increased the risk of cooling failure.

The company had only equipped the reactor with a simple cooling system without a backup.

The CSB recommends companies to identify and evaluate reactive hazards, implement safety systems, and manage process changes.

Education and awareness are key to managing reactive chemistry hazards, as many incidents occur due to lack of understanding.

The CSB recommended incorporating education about reactive hazards into chemical engineering curricula.

Improved industry practices and increased education will help prevent future chemical accidents.

Transcripts

[Music]

[Sound of sirens]

Narrator: On December 19, 2007, a powerful explosion and fire occurred at T2 Laboratories,

a small chemical producer in Jacksonville, Florida.

The blast killed and injured workers, destroyed T2 Laboratories and damaged four nearby businesses.

Windows blew into offices [sound of explosion], striking workers with flying glass.

Visscher: The explosion at T2 Laboratories is one of several accidents that the CSB has investigated,

caused by runaway chemical reactions.

Accidents resulting from reactive hazards occur too frequently and often have serious consequences.

[Music]

Hall: Behind me on this concrete pad there used to stand a structure, some 50-feet high,

that had a reactor vessel in it,

in which the company that operated here, T2 Laboratories, Incorporated,

manufactured a chemical known as methylcyclopentadienyl manganese tricarbonyl or MCMT for short.

The entire structure and reactor vessel were blown away in the explosion.

Narrator: T2 produced MCMT, a gasoline additive, in batches using a 2500 gallon reactor.

An operator controlled the process with a computerized system in a nearby control room.

In the first step, liquid chemicals and sodium metal were loaded into the reactor,

heated and then mixed with an agitator.

The reaction produced hydrogen, which was vented to the atmosphere.

In normal operations, when the temperature reached 300 degrees Fahrenheit,

the operator would turn off the heating system.

But because this reaction was exothermic or heat-producing,

the temperature inside the reactor would continue to rise.

At 360 degrees, operators would begin to periodically fill the reactor's cooling jacket with water.

As the water boiled, heat was removed, controlling the temperature.

However, on the day of the accident, the CSB found that the operator tried to cool the reactor as usual,

but the cooling system likely malfunctioned,

perhaps due to a blockage in the water supply piping or a valve failure.

The temperature and pressure inside the reactor began to rise uncontrollably, in a runaway chemical reaction.

T2's co-owners returned to the plant after a worker called to report the cooling problem.

While one owner searched for the plant mechanic, the other went to the control room.

Concerned about a possible fire, he warned employees to move away from the reactor.

Inside the reactor, the pressure was still increasing,

reaching 400 pounds per square inch and bursting the rupture disc.

Witnesses heard a sound like a jet engine, as high-pressure gas began to vent from the reactor.

[Hissing sound]

But it was too late.

Within ten seconds, there was a massive explosion, equivalent to about 1400 pounds of TNT.

[Sound of explosion]

Narrator: The blast damaged buildings over 1500 feet away.

Debris rocketed up to a mile.

The co-owner and the operator in the control room were killed.

Two operators further away, died from flying debris.

Thirty-two other people were injured, including 28 at nearby businesses.

Senterfitt: This facility housed multiple types of chemicals.

It was kind of a mass storage of everything you can think of

and it was all mixed together and it was all burning together.

And for our perspective, from the hazardous materials side, it makes kind of a worst-case scenario.

Narrator: Damage from the explosion was so severe, four nearby buildings were condemned.

Ayers: My office personnel heard a whistling sound in the area and as they looked out the window,

they saw an orange glow, [sound of explosion] which was the blast coming off of the explosion.

And it came to our offices and it blew in all the windows in our office trailers. [Sound of explosion]

Ayers: Immediately, it was a shock or a surprise; then all of us were shaken afterward.

[Music]

Narrator: In 2002, the CSB completed a study on reactive chemical hazards.

The study identified 167 serious accidents involving uncontrolled chemical reactions between 1980 and 2001,

causing 108 deaths and hundreds of millions of dollars in property damage.

Hall: When mixing chemicals that have an exothermic reaction,

you need to be aware of the amount of energy that could be released by the reaction,

to prevent vessels from bursting like the one that happened here.

[Sound of explosion]

Narrator: T2 developed its MCMT process using a one-liter reactor.

The company then scaled up the process directly to full production volume in the 2500-gallon reactor.

After 41 batches, T2 increased the batch size further by one-third.

As the scale of the reaction increased, effective cooling became ever more difficult.

During 175 production runs, making MCMT,

T2 periodically experienced problems, such as unexpected temperature increases.

But the company never fully investigated the causes.

And T2 had only equipped the reactor with a simple cooling system using city water.

When the system malfunctioned, there was no backup cooling immediately available to control the reaction.

Hendershot: The most important thing to managing reactive chemistry hazards

is that you have to have a thorough and complete understanding of your chemistry under design conditions

and also under all foreseeable abnormal conditions.

Narrator: The CSB has noted that to prevent reactive chemical accidents,

companies should identify and thoroughly evaluate reactive hazards in their processes.

Implement appropriate emergency pressure relief systems and other design safeguards.

Develop effective operating procedures and training programs

and carefully manage any changes to existing processes.

And plan for possible accidents, including evacuation drills and emergency response exercises.

Although T2's owners had undergraduate degrees in chemistry and chemical engineering

and experience in the chemical industry,

neither had been trained on how to recognize or control reactive hazards.

Hendershot: A large portion of the incidents have occurred,

because the people who are actually running the process were not aware,

either of the existence of the reactive chemistry hazard

or of the potential magnitude of the consequences associated with that chemical reaction hazard.

So a lot of the problem, I think, is education and awareness.

Narrator: The Board noted that multiple sources of information are available on how to control reactive hazards,

including publications from the Center for Chemical Process Safety,

the Design Institute for Emergency Relief Systems

and the U.K. Health and Safety Executive.

Following the T2 investigation, the CSB recommended that the American Institute of Chemical Engineers

work to incorporate education about reactive hazards into college-level chemical engineering curricula.

Visscher: Reactive chemical hazards continue to be a too frequent cause of chemical accidents.

Improved industry practices and increased education will help prevent these tragedies.

Thank you for watching this CSB Safety Video.

[Music]