Respondent owned and operated a primary metal products manufacturing facility that produces annually over 300,000 tons of powdered metal which is used in the production of automotive parts. Hydrogen is handled in the production of powdered metal, and hydrogen is a regulated flammable substance listed under 40 C.F.R. § 68.130.
The Facility receives scrap iron and steel that is melted and poured into a machine called an atomizer which uses high pressure to cool the molten metal turning it into a wet metal powder or slurry. From the atomizer, the metal slurry is dewatered and dried in rotary driers or kilns. After drying, the powder is screened by an electric shaker, to remove unwanted larger particles and conveyed to storage bins prior to being annealed. The powdered metal is placed on 100-foot long conveyor belts or bands which run through one of 12 annealing band furnaces at the Facility. After passing through the annealing furnaces, the metal powder is transferred to the blending line where additives are mixed with the powder and then the powder is packaged and stored in the warehouse for shipment. The process of annealing uses a hydrogen atmosphere to reduce the iron by removing the oxides and preventing oxidation. Hydrogen is conveyed to the annealing furnaces via pipes in a trench under the floor and after annealing, the hydrogen is vented through a separate hydrogen vent pipe.
On May 27, 2011, a hydrogen explosion occurred while an employee was attempting to remove a metal plate covering the hydrogen vent and supply pipes in the floor trench to identify the source of a hissing sound of leaking gas. The floor trench contained water which was in contact with the hydrogen vent and supply pipes.
Prior to the May 27, 2011 hydrogen explosion, Respondent had no program for inspecting, testing, and maintaining the mechanical integrity of its hydrogen vent and supply piping. At the time of the May 27, 2011 explosion, the hydrogen vent pipe had corroded, resulting in a leak that caused the hissing sound.
ALLEGED VIOLATIONS