FACTS Database with hazardous materials used for industrial safety

FACTS
Database with hazardous materials used for industrial safety
maintained by the Department of Industrial Safety of TNO
Coded Accident Abstract
Identification
Type
Class
Abstr
Abstr
Address
Adate
Time
Activ
Loctn
Dchem
Dtype
Value
***
Extended abstract english
Extended abstract french
j
1970
Accident Nr.
11542
Text
-
Processing
Chemical factory
Org-acids (prod.)
Chemical industry
2247
Batch
Acetic acid
-
Value
Human-failure
Text
Too high concentr. aldehyde
Value
Draining
Reactor
Line
Text
Drain
Reaction system
2/M3
Reaction solvent
Air separation unit (asu)
20/M3
7.7/M3 of reaction solvent
This was thought to be 2/M3
Lesser as usual to expedite the oxidation process
-
Cause
Type
Cause
Description
Type
Occur
Eqinv
Eqinv
Qcont
Chem
State
Text
Occur
Eqinv
Occur
Eqinv
Qcont
Load
Text
Text
Chem
State
Chem
State
Chem
State
Occur
Text
Occur
Conctr
Chem
State
Occur
Occur
Chem
Flow
Chem
Flow
Chem
Chemical n.o.s.
Liquid
Maintenance
Separator
Fill
Reactor
Acetaldehyde
Liquid
Oxygen (gas)
Gas
Manganese acetate
(t.hydrate)
Powder
Wrong-action
Wrong-composition
Aldehydes
Liquid
Human-operations
System-operations
Aldehydes
Oxygen (gas)
Manganese acetate
(t.hydrate)
Forgot to refill reactor with
The drained reaction solvent
Higher than about 2%
5.5% about
Starting up the reaction
Circulation
500/l/h
80/Nm3/h
-
Flow
Occur
Temp
Time
Occur
Occur
Temp
Occur
Chem
Occur
Occur
Time
Occur
Time
Eqdm
Eqdm
Eqdm
Eqdm
Lesson
Heating
Overheating
Run-away-reaction
Ignition
Aldehydes
Explosion
Fire
Fire fighting/Emergency
response
Reactor
Measure-device
Window
Window
10/l/h
40/c
2100
175/c
Self-ignition of
2247
2320 fire extinguished
Upper half
Many of these and lines etc
Broken windows of nearby
Private houses
See extended abstract
Scene
Type
Scene
Scene
Scene
Scene
Value
Text
Self-ignition and explosion
Due to too high concentration
Of acetaldehyde in reaction
Liquid.
EXTENDED ABSTRACT ENGLISH
At the starting time of the reaction after the termination of the induction period, the
concentration of aldehyde was about 5.5% (the normal concentration is about 2%).
The rate of oxidation of the aldehyde by oxygen is known to be proportional (1.5:1) to
the aldehyde concentration.
Normally, outer-circulating liquid returns the top of the reactor column and falls down in
a droplet or mist form (that is, droplet containing catalyst). It is presumed that a rapid
reaction started at the top of the column, then the temperature of thermal insulated
droplets increased, the reaction rate was accelerated, and, as a result, the temperature
reached the ignition temperature of the aldehyde (175/C). That is, the accident can be
mainly attributed to an excessively high concentration of aldehyde.
Lessons learned (safety measurements)
1.
The level indication improved and provided with a alarm.
2.
Limitation of the aldehyde concentration in the reaction liquid.
3.
Clarification of work norm.
EXTENDED ABSTRACT FRENCH
Une explosion et un incendie se produisent dans un complexe chimique fabriquant de
l'acide ac??tique. A la suite de l'oubli de l'adjonction d'un solvant dans un r??acteur, la
concentration en ac??tald??hyde est devenue trop importante (5.5% pour 2%).
L'??l??vation de la temp??rature a amen?? le produit ?? son point d'auto-inflammation
et la colonne de r??action a explos??. Le r??acteur est partiellement d??truit, ainsi que
des fen??tre des maisons voisines.