Bhopal Disaster

We are,

1. Asim Hameed

2. Abdullah Liaqat

3. Asif Muaviah

4. Aftab Zafar

5. Muhammad Haseeb

6. Sohail Afzal

7. Muhammad Irfan

GROUP # 3
What happened at Bhopal

• On 2-3 December 1984, one of the world’s worst industrial disasters happened in Bhopal, India.

• Methyl isocyanate (MIC) gas leaked from a pesticide plant owned by Union Carbide India Limited.

• The deadly gas spread and killed at least 4,000 people, while causing significant morbidity and
premature death for thousands more.

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Introduction
• Union Carbide India Limited (UCIL)
• A pesticide company
• Indian Subsidiary of Union Carbide Corporation (UCC)
• Located in Bhopal, Madhya Pradesh, India

• 1969, UCIL started its operation in India

• Phosgene, Monomethylamine, Methyl Isocyanate (MIC) and the pesticide Carbaryl were
manufactured here.
• UCC produced carbaryl using MIC as an intermediate.
• After the Bhopal plant was built, other manufacturers including Bayer produced carbaryl without
MIC, though at a greater manufacturing cost.

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Chemical Produced in UCIL

Methylamine (1) reacts with phosgene (2) producing methyl isocyanate (3)

which reacts with 1-naphthol (4) to yield carbaryl (5)

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Physical and Chemical Properties of Methyl
Isocyanate• Methyl Isocyanate (C H NO)
2 3

• Liquid form
• Volatile , Flash Point:20ºF,(-7 Deg C)
• Colourless
• Strong, sharp odour
• Molecular weight: 57.05
• Boiling point (760 mm Hg): 102ºF (39.1ºC)
• Freezing point: -49ºF
• Vapor pressure: 348 mm Hg at 68ºF (20ºC)
• Vapor density: 1.42 (air = 1.00)
• Water solubility: Reactive 6.7% at 68ºF (20ºC)
• Flammability: Highly flammable
• Flammable Range: 5.3% to 26% (concentration in air)
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Emergency Information
Hazard Rating NFPA
Flammability 3
Reactivity 2
Flammable and Reactive
Poison Inhalation Hazard
Do not use water
Poisonous Gases are produced in fire
Containers may explode in fire

Hazard Rating Key: 0-minimal, 1-slight, 2-moderate, 3-serious, 4-severe

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What Caused the Accident
• Water entered MIC tank (E-610)

• As per third party Investigation,

• Water leaked into tank of MIC (E-610) because safety systems couldn’t respond

• As per UCC’s CEO,

• It was deliberate attempt, but mgmt. couldn’t provide evidence

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…What Caused the Accident
• MIC tank alarm had not worked for 5 years
Poor Maintenance • Flare tower and vent gas tower had been cut of service for 5 months
• Refrigeration system was idle to save the cost

Poor • Leakages are routine

Management • MIC leaked in 1982, affected 18 workers
• Equipment were not calibrated
towards Safety

Repressive Style • Workers were forced to use English manual while only few could
understand English appropriately
management

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Contribution to Negligence
• A pipe leaked? Don't replace it.
• MIC workers needed more training. They could do with less.
• The MIC tank alarms had not worked for four years.
• The flare tower and the vent gas scrubber had been out of service for five months before the disaster.
• To reduce energy costs, the refrigeration system was idle. The MIC was kept at 20 degrees Celsius,
rather at 4 deg C as per manual
• Carbon steel valves were used at the factory, even though they corrode when exposed to acid.
• According to the operators the MIC tank pressure gauge had been malfunctioning for roughly a week.
• UCC admitted in their own investigation report that
most of the safety systems were not functioning on the night of December 3, 1984

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After Disaster
• It is estimated that total deaths are about 40,000 upto 20 years
after disaster.
• It is estimated 1,00,000 to 2,00,000 people have permanent
injuries.
• Reported symptoms are eye problems , respiratory difficulties,
immune and neurological disorders, cardiac failure secondary to
lung injury, birth defects among children born to affected
women.

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Rehabilitation
• Immediate relief was decided two days after the tragedy.
• Relief measures commenced in 1985 when food was distributed for a short period
and ration cards were distributed.
• Widow pension of the rate of Rs 200/per month (later Rs 750) was provided.
• One-time ex-gratia payment of Rs 1,500 to families with
• monthly income Rs 500 or less was decided.
• 2,486 flats in two- and four-story buildings were constructed in the "Widows
colony" outside Bhopal. The water did not reach the upper floors. It was not
possible to keep cattle. Infrastructure like buses, schools, etc. were missing for at
least a decade.
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Was the disaster preventable ?

• Reduce the fats but never cut the muscles.

• Equipment Integrity and Reliability
• Preventive Maintenance
• Inherently safe Design
• Employees Participation in HIRA
• Reduce Human Errors
• Process Hazards Analysis
• Appropriate Training(s)

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Reference(s)
https://www.youtube.com/watch?v=HsuUQzhP2Ds
https://www.icheme.org/media/12438/lpb269_pg11.pdf