On July 17, the U.S. Chemical Safety and Hazard Investigation Board (CSB) released an update on its investigation into a January 2023 explosion and toxic chemical release at the Honeywell Performance Materials and Technologies facility in Geismar, La. A reboiler at the facility exploded, leading to the release of over 870 pounds (lb) of hydrogen fluoride (HF) gas and nearly 1,700 lb of chlorine gas—both highly toxic substances.
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Following the incident, local officials closed nearby highways, and workers at the facility sheltered in place. No injuries occurred as a result of the release. Honeywell, which manufactures refrigerants and other products at the facility, estimates the property damage to be approximately $4 million.
The CSB update revealed that the most recent mechanical integrity inspections of the reboiler before the explosion were in September 2020, when Honeywell used ultrasonic thickness testing, and in October 2021, when Honeywell conducted an internal visual inspection of the reboiler.
Based on the September 2020 inspection, Honeywell had estimated 1.1 years of remaining service life for the reboiler shell. Following the October 2021 visual inspection, Honeywell personnel recommended that the shell be replaced at the next shutdown opportunity.
In January 2022, Honeywell initiated a project to purchase a replacement reboiler shell. Management approved the project but didn’t purchase or install a replacement shell before the reboiler ruptured on Jan. 23, 2023.
On that date, a boiling liquid expanding vapor explosion (BLEVE) occurred due to the conditions inside the reboiler at the time of failure. The BLEVE resulted in the sudden release of HF, chlorine gas, and other substances from the reboiler, the distillation column, and other ancillary equipment, according to the CSB.
Board investigators continue to gather facts and analyze several key issues, including:
- Honeywell’s mechanical integrity policies and practices;
- Honeywell’s project management policies and practices; and
- Relevant facility, corporate, and industry standards.
The CSB isn’t an enforcement agency and doesn’t issue citations or fines but makes recommendations to companies, industry organizations, labor groups, and regulatory agencies, including the Environmental Protection Agency (EPA) and Occupational Safety and Health Administration (OSHA). Board members are appointed by the president subject to Senate confirmation.
In other recent CSB news, the agency has urged chemical companies to prepare their facilities for a “harsh” hurricane season ahead to avoid potential catastrophe. Read more about that here.