Hazardous Materials

Lack of ventilation, fixed gas detection, draining hazardous materials SOP, and personal gas monitor leads to asphyxiation fatality

During the morning of February 24, 2023, an unknown amount of hydrocarbons and hydrogen sulfide were released, fatally injuring an employee inside an enclosed building at an oil and gas facility in North Dakota. The hydrocarbons and hydrogen sulfide displaced the oxygen in the building, and the employee asphyxiated in the oxygen-deficient atmosphere. The employee…...

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Contractor’s Scissor Lift causes 22,000 pound fatal NH3 release

On December 19, 2022, at approximately 11:10 a.m., an accidental release of 22,000 pounds of anhydrous ammonia occurred from the NH3 refrigeration process at a food processing facility in Norwood, Massachusetts. Exposure to the toxic ammonia vapor fatally injured one contract worker and seriously injured another contract worker. In addition, the release caused about $4…...

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Catastrophic Failure of NH3 Compressed Gas Cylinder

On Thursday, 1/15/2025, a 150-pound compressed gas cylinder of Anhydrous Ammonia (NH3) catastrophically failed while it was being transported in by a cylinder delivery vehicle. Three (3) people were hospitalized from this event: the truck driver, a poll plaza worker, and a security guard. As of 1/17/26, they are in stable condition. The video and…...

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Contractor’s Scissor Lift leads to $380 million in damages, closure of the facility, and 200 jobs lost

On June 14, 2021, at approximately 6:50 a.m., an accidental release of mineral oil occurred. The mineral oil ignited, causing a fire. The event resulted in $380 million in property damage and the permanent closure of the facility. Before the incident, the facility employed approximately 200 people. Leading up to the incident, the facility had…...

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Changing Cl2 1-ton cylinder leads to “Life Flight” ride

On December 3, 2020, at approximately 2:30 p.m., an accidental release of chlorine gas occurred at a plastics facility and seriously injured one employee. At the time of the incident, four (4) employees were involved in replacing an empty chlorine container with a full 2,000-pound (one-ton) container at the facility’s Ethylene Glycol unit. The unit…...

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Line Break Gone Bad w/ Contractor (Silicon Tetrachloride)

On July 24, 2020, at 1:20 p.m., an accidental release of approximately 100 milliliters of silicon tetrachloride seriously injured two contract workers. At the time of the event, contract workers were disassembling a 2-inch flange to remove a blind (a solid metal plate used to isolate equipment) before reinstalling a section of piping that had…...

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Temporary transfers of caustic solution through a hose results in serious burns

On April 11, 2020, at 11:25 p.m., a spent caustic release occurred. One (1) operator was seriously injured by skin exposure to the corrosive liquid. At the time of the incident, the operator was implementing a temporary procedure to remove liquid from a chemical hose connected to fill a portable storage tank (“frac tank”) that…...

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Line/Equipment Opening Gone Bad (1 lb. of NH3)

On January 7, 2023, at approximately 4:55 p.m., about one (1) pound of anhydrous ammonia was released at the facility. Exposure to the toxic ammonia gas seriously injured one refrigeration technician. At the time of the incident, the employee was working on an ammonia compressor that was “out-of-service”. The ammonia compressor is used in the…...

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A Process Safety WIN! (LPG Piping inspection)

A plastics company was having its 5-year piping inspection done, and the inspectors found a crack in a valve under the 30,000-gallon storage tank. As a precaution, both tanks were drained to safely make the necessary repairs. As part of the facility’s standard protocol, the company called the fire department and conducted preventive evacuations…. Membership...

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WRONG Chemical – WRONG TANK (nitric acid and phosphoric acid)

A bulk unloading incident created an orange chemical cloud, injuring four (4). The exothermic reaction occurred when phosphoric acid was accidentally unloaded into a 10,000 L (2640 gallons) nitric acid storage tank…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Static Electricty ignites vapors in fatal event

A fire broke out at a factory on Jan. 8, 2026, severely injuring a worker, 30, who died five days later on Jan. 13, 2026, according to police. The explosion occurred during a chemical mixing operation…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Triple Fatality in Sewer by Asphyxiation (Video)

The three Syrian workers who died of suffocation in the Marj area of West Bekaa, Lebanon in an incident that occurred around August 14, 2025, were not identified by name in the initial news reports. News coverage confirmed that the bodies of the three men were removed from the manhole by the Masnaa Civil Defense…...

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