Equipment Filling and Mixing - Incidents | AIChE

Equipment Filling and Mixing - Incidents

Last updated March 15, 2019 | Element: Incidents

  1. Inadvertent mixing of sulfuric acid and sodium hypochlorite produced a cloud containing chlorine and other compounds. The cloud impacted workers onsite and members of the public in the surrounding community. The incident occurred during a routine chemical delivery of sulfuric acid from a chemicals cargo tank vehicle (CTMV) at the MGPI facility tank farm.                           

  1. Several construction employees working near a collection pit were overcome with hydrogen sulfide gas. The gas was released nearby when sodium hydrosulfide was accidentally mixed with sulfuric acid. Three workers collapsed almost immediately and three others tried to rescue them. Two of those rescuers also collapsed. In all, ten workers were exposed to the toxic gas. Two died and eight others were injured.                                                                             
  2. (April 25, 2002)  An explosion and fire occurred in a 10-story mixed-occupancy building in the Chelsea district of Manhattan, New York City. Employees had just finished consolidating hazardous waste from smaller containers into two larger drums. The wastes, nitric acid and lacquer thinner, were incompatible, and an explosion occurred. Thirty-six people were injured, including six firefighters and 14 members of the public. The building was extensively damaged.

  1. (August 12, 2015)  A series of explosions killed 173 people and injured hundreds of others at a container storage station at the Port of Tianjin. The first two explosions occurred within 30 seconds of each other at the facility. The second explosion was far larger and involved the detonation of about 800 tons of ammonium nitrate. Fires caused by the initial explosions continued to burn uncontrolled throughout the weekend, resulting in eight additional explosions three days later. In addition to vast quantities of sodium cyanide and calcium carbide, paperwork was discovered showing that 800 tons of ammonium nitrate and 500 tons of potassium nitrate were at the blast site.

  1. (May 2013, Portland, Oregon)  A supplier truck driver pumped a mixture of nitric and phosphoric acids into a tank containing sodium hypochlorite at a dairy.

  1. (October 2007, Frankfurt, Germany)  Hydrochloric acid was accidently transferred into a sodium hypochlorite tank. Approximately 200 kg of chlorine were released, and more than 60 people were injured. The operator who finally stopped the transfer was fatally injured from exposure to chlorine.

  1. (August 2001, Coatbridge, UK)  A tanker driver transferred sodium hypochlorite solution and hydrochloric acid into the same tank at a swimming pool. 30 people required medical treatment.

  1. (August, 1993, Stockholm, Sweden)  A truck driver pumped phosphoric acid into a storage tank containing sodium hypochlorite at a swimming pool.

  1. (March 1985, Westmalle, Belgium)  Hydrochloric acid was pumped into a tank containing residual sodium hypochlorite.

  1. (November 1984, Slaithwaite, UK)  A plant expected a delivery of sodium hypochlorite, but received ferric chloride solution (an acidic solution) instead. The ferric chloride was unloaded into the sodium hypochlorite tank.

  1. (September 1984, Hinckley, UK)  Hydrochloric acid was unloaded into a tank containing sodium hypochlorite.