Mary Kay O’Connor Process Safety Center

Making Safety Second Nature

SYNTHRON EXPLOSION
Case Study: Runaway Chemical Reaction and Vapor
Cloud Explosion

Linh Dinh
Maryy Kay
y O’ Connor Process Safety
y Center

Presentation to
Steering Committee
February 12th 2009
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 Background Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Company profile
• Synthron Inc
Inc. plant
• Location: Morganton, North Carolina
• Produce acrylic polymers
Reaction overview
• Free radical polymerization in various flammable
solvents: Acrylic monomers Æ Acrylic polymers
Jan 31, 2006, the explosion occurred
• In a 1,500 gallon reactor
• At 75 psig maximum operating pressure

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 Background Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

• Facility layout

Figure 1. The Synthron facility layout

http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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 January 31, 2006 Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Operating procedure
• Monomer and solvent: transferred
to reactor
• Heat the mixture using steam
• Add the initiator solution

Before the incident

• An order: 12 % larger quantity

On that day …
• Recipe: scaled up 12 %
• Additional monomer: added into
Figure 2
2. The polymerization reactor the initial charge

http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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 A critical mistake Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

ƒ Total of monomer 45 %
ƒ Monomer concentration 27%
ƒ Atmospheric boiling point
temperature of the mixture
5°C (9°F).

Adapted from CSB website

• More than doubled the rate of energy was released
• Reactor pressure increased
• Fl
Flammable
bl vapors vented d to the
h building
b ildi
• Around 11:30 am, the explosion happened
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 Consequences Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Adapted from CSB website

• The facility was destroyed
• Nearby community: damaged
• Glass was broken up to one-third of a mile from the site
• The fires were extinguished the next day
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 Contributing factors M a r y K a y O ’C o n n o r P ro c e s s S a fe ty C e n te r
M a k in g S a f e ty S e c o n d N a tu re

I ff ti control
Ineffective t l off product
d t recipe
i changes
h

Clean Condenser + Emergency Jacket Cooling

Maximum heat Fouled Condenser + Emergency Jacket Cooling

output: increase
at least 2.3 times Cooling Capacity of Clean Condenser

Cooling Capacity of Fouled Condenser

Modified recipe
Standard
recipe

Fi
Figure 2
2. R
Results
lt off reaction
ti calorimetry
l i t (by (b CSB iinvestigators)
ti t )

Lack of hazard recognition

• No PHA or testing
• Personnel: less experience
http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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 Contributing factors
Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Chemical Process Safeguards

• No high pressure alarm
• No automatic emergency cooling water
• No automatic or remotely operated venting
• Visually
y checked the flow of condensed solvent
Process Equipment Fouling

Reduce condenser
capacity
p y at least 25%

http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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 Contributing factors Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Lack of process safety information

• Personnel: poorly prepared to recognize the hazards
• Estimate production batch sizes based on past experience

Manway Bolting Practice

Secure the manway Leak at 23 psig << 75 psig,

using only four of the reactor’s maximum
18 clamps . allowable
ll bl working
ki pressure

http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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 Lessons Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Identify and Control Reactive Hazards

• What can go wrong
www.oshatrain.org
• Implement adequate safeguards

Control changes

www.esml.com

Maintain process equipment capacity

• Reactor condenser, …

www.udmc.biz

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 Lessons Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Train personnel on hazards and

procedures
• Manway
• Recipe changes,
g …
http://www.aecga.com/images/Safety_training.gif

Prepare for emergencies

• Adequate emergency response
planning by Synthron could
prevent the death and serious
injured caused by the explosion
http://plrwholesaler.com/pro.plr/emergency.jpg

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 Acknowledgement Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

Dr. Mannan
Dr. Rogers
All of members of MKOPSC

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 Mary Kay O’Connor Process Safety Center
Making Safety Second Nature

THANK YOU

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