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Key Takeaways:
- In May 2019, a fatal explosion occurred at an AB Specialty Silicones facility due to a mixture of incompatible chemicals.
- The explosion led to the unfortunate loss of four workers’ lives, injured one more, and caused extensive damage to the facility and nearby businesses.
- Human error, inadequate safety procedures, and a lack of an effective hazard analysis program contributed significantly to the catastrophe.
- The incident calls for necessary reforms in regulatory safety standards to prevent such accidents in the future.
The Incident: AB Specialty Silicones Explosion
On May 3, 2019, AB Specialty Silicones, located in Waukegan, Illinois, experienced an unfortunate catastrophe. An explosive incident at the facility claimed the lives of four workers, injured a fifth, and left the facility in ruins. This incident also inflicted extensive damage to nearby businesses, sending shockwaves across the industry.
The explosion occurred due to an unintentional mix of two incompatible chemicals, leading to a chain reaction that released a volatile substance – hydrogen gas – within the building. This accidental mixture came about when an operator, working the second shift, misidentified two chemical drums that appeared identical but contained different substances: potassium hydroxide (KOH) and a polymer known as Andisil XL 10.
In an attempt to manufacture the next batch of an emulsion product, the operator unintentionally added the KOH solution to the mixture instead of the XL 10. The ensuing chemical reaction overflowed the tank, releasing flammable hydrogen gas into the production building.
The Moments Leading to the Tragedy
The operators present recognized the adverse reaction, but they did not know that it had led to the release of hydrogen gas. Despite an attempt to vent the building, the action came too late. The accumulated gas ignited, causing a massive explosion.
In hindsight, if there had been written procedures specifying the storage of incompatible chemicals in separate areas or differently colored drums, this confusion and resultant human error might have been prevented. Furthermore, the production building lacked a hazardous gas detection system. This absence was a significant oversight, given that hydrogen gas is virtually indistinguishable from ordinary air, emphasizing the importance of such a safety system.
Safety Oversights and The Aftermath
The explosion raised concerns about AB Specialty Silicones’ safety measures. Notably, the company did not implement an effective hazard analysis program, a lapse that contributed to the severity of the incident.
After a smaller chemical explosion in 2014 resulted in temporary hearing loss for a worker, AB Specialty had identified a “lack of comprehensive hazard analysis” as a factor. However, necessary improvements were not made in time to prevent the 2019 disaster. This event highlighted the deficiencies in AB Specialty’s process safety culture, which had failed to prioritize effective safety management systems.
A well-designed ventilation system might have mitigated the severity of the explosion. Ideally, a local exhaust ventilation system could have helped reduce the concentration of the volatile gas within the building. Moreover, the workers were not equipped with the necessary emergency preparedness training to handle such a situation effectively, resulting in precious lost time and, ultimately, lives.
A Call for Enhanced Regulations
What’s most concerning is that despite using chemicals that could cause dangerous reactions, AB Specialty was not required by existing regulations to implement process safety measures. This incident, therefore, served as a wake-up call for regulatory bodies to take a closer look at their safety standards.
The U.S. Chemical Safety and Hazard Investigation Board (CSB) called for the Occupational Safety and Health Administration (OSHA) to amend its process safety management standard. The aim was to attain more comprehensive control of reactive hazards and require the evaluation of such hazards.
Additionally, CSB recommended the Environmental Protection Agency (EPA) revise its accidental release prevention requirements under its risk management plan rule. This change would encompass catastrophic reactive hazards that could impact the public.
Conclusion: Lessons Learned
The AB Specialty Silicones explosion serves as a stark reminder of the potential dangers of mishandling chemicals and the profound need for appropriate safety measures in industries dealing with hazardous substances.
For companies, this incident underscores the importance of maintaining an effective hazard analysis program, ensuring clear identification of chemicals, and providing comprehensive emergency preparedness training for all workers.
Regulatory bodies and companies alike must learn from this incident, enforcing stricter regulations and implementing robust safety systems. Only then can we hope to prevent such tragedies in the future and ensure the safety and well-being of workers in hazardous industries.
