Accident: Toxic Chemical Vapor Cloud Release
Major Damage: 154 Treated, 5 Hospitalized for Toxic Chemical Exposure
Date: April 12, 2004
Location: Dalton, Georgia
EVENTS
Major Accident Scenario:
On April 12, 2004, at approximately 9:30 PM, a reactor at MFG Chemical’s Callhan Road facility in Dalton, Georgia; experienced a runaway reaction during the first production synthesis of triallyl cyanurate (TAC). The highly exothermic reaction over pressured a 4000 gallon reactor, causing the manway to fail and burst open, in addition, the emergency rupture disc was activated. A release of highly toxic and flammable allyl alcohol vapor and toxic allyl chloride was vented directly into the atmosphere, exposing and injuring facility employees, nearby residents, and emergency responders. [1] Approximately, 200 families and local business owners were evacuated, while the reaction continued to release the dense vapors. Approximately 154 people required denomination and treatment for trouble breathing and eye and skin irritation, in addition, five people were hospitalized overnight and one MFG employee sustained minor chemical burns.
Pre-accident Conditions:
This event involved three companies: MFG Chemical, Inc. (MFG), GP Chemical (GPC), and Lyondell Chemical Company (Lyondell). MFG was chosen by GPC to manufacture TAC because of the size of the reactor and they had the additional equipment needed for the synthesis.
The synthesis of TAC requires allyl alcohol and Lyondell deals exclusive in the sell and distribution of allyl alcohol. Lyondell requires a visit to a company’s facility to ensure and assess the preparedness of the facility to handle the allyl alcohol. After visiting MFG’s facility, Lyondell concluded that they would be able to...
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...hrough of procedures and recommendations.
Lyondell should revise their checklist and place more emphasis on the thresholds of allyl alcohol associated EPA Risk Management Program regulation and OSHA PSM standard.
In addition to the various chemical plants, the state of Georgia also has a responsibility to ensure compliance of the Right-to-Know Act, which includes reviewing Local Emergency Plans and designating responsibility to an agency to help local authorities obtain and use Risk Management Plans for facilities.
REFERENCES
U.S Chemical Safety and Hazard Investigation Board. (2006, April). Toxic Chemical Vapor Cloud Release. (Report No. 2004-09-I-GA). Dalton, Georgia.
U.S. Environmental Protection Agency. (2008, March). Motion for Accelerated Decision. http://www.epa.gov/oalj/orders/mfg-chem-dad-032408.pdf (Docket No. CWA-04-2008-5192). Washington, D.C.
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The United States Enrichment Corporation (Producer). (2013). USEC issues WARN act notices to Paducah Gaseous Diffusion Plant workers [Video file]. Retrieved from http://www.usec.com/news/usec-issues-warn-act-notices-paducah-gaseous-diffusion-plant-workers
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U.S. Chemical Safety and Hazard Investigation Board. (March 20, 2007). Final Investigation Report. Retrieved July 26, 2010, from U.S. Chemical and Safety Board: http://www.csb.gov/assets/document/CSBFinalReportBP.pdf
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FM 4-02.285, Multiservice Tactics, Techniques and Procedures for Treatment of Chemical Agent Casualties and Conventional Military Chemical Injuries (2007, CDC Emergency Preparedness and Response, (2003, April 3). This page includes links September 18), Headquarters, Department of the Army
Stalcup, A. (2013). Surviving toxic work environments. Analytical & Bioanalytical Chemistry, 405(4), 1145-1147. Retrieved from EBSCOhost Database (AN: 84944726)
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Wood, A. (2005, August 10). Chemtura: Making a merger work. Chemical Week, 167, pp. 17-19.
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