Chemical Plant & Refinery Explosion Lawsuits

• The Kuraray America Plant Explosion – Texas

  On May 19, 2018, the Kuraray America Plant in Pasadena, Texas, experienced a devastating explosion that had far-reaching consequences for both the facility and the surrounding area. The explosion occurred in a polyvinyl alcohol production unit and led to a massive fire that raged for several hours. Fortunately, no fatalities were reported, but the incident resulted in 21 people suffering injuries, including some severe burns. The blast also caused significant damage to the plant, with debris scattered across the site and the surrounding neighborhood.

  Investigations into the incident revealed that a combination of factors, including equipment failure and inadequate safety procedures, contributed to the explosion. In the aftermath, the company committed to improving its safety protocols and making necessary upgrades to prevent similar accidents in the future.

• The ExxonMobil Olefins Chemical Plant Explosion – Texas

  On July 31, 2019, a catastrophic explosion occurred at the ExxonMobil Olefins Chemical Plant in Baytown, Texas, sending shockwaves through the industrial and local communities. The explosion resulted in a significant fire and forced the plant to shut down, affecting the production of chemicals and causing concerns about air quality. While no fatalities were reported, 37 people sustained injuries, with one person being hospitalized.

  The ExxonMobil Olefins Chemical Plant explosion highlighted the ongoing challenges and risks associated with the petrochemical industry, particularly the need for robust safety measures and equipment maintenance. It also raised concerns about the potential environmental and health impacts of such incidents in heavily industrialized regions.

• The Phillips 66 Chemical Plant Explosion – Texas

  On October 23, 1989, the Phillips Disaster struck the Houston Ship Channel in Pasadena, Texas, when a series of explosions and fires erupted at the Phillips 66 chemical plant, resulting in the deaths of 23 workers and injuring over 130 others. The incident occurred during routine maintenance when a flammable hydrocarbon mixture escaped from a pipe, ignited, and triggered a chain reaction of explosions and fires that engulfed the facility. This disaster sent shockwaves through the community and the petrochemical industry, prompting extensive investigations and leading to significant changes in safety regulations and procedures.

  The Phillips Disaster exposed serious safety shortcomings within the chemical industry, including inadequate emergency response plans, insufficient training, and outdated equipment. As a result of the explosion, safety regulations and practices in the petrochemical sector were reevaluated and enhanced to prevent similar disasters in the future.

• Phillips 66 Wood River Refinery Fire – Illinois

  On February 10, 2019, a fire erupted in the Distilling Unit #2 at the Phillips 66 Wood River Refinery during the startup phase following a scheduled maintenance outage. The incident occurred due to an operational error when operators mistakenly opened the wrong valve, directing hydrocarbons into a heat exchanger that should have been bypassed. As a result, liquid hydrocarbons entered the exchanger’s shell side, causing an over-pressurization that released hydrocarbons through an open pipe. These hydrocarbons subsequently sprayed onto the exchanger platform structure, encountering an ignition source, leading to a fire that lasted approximately 50 minutes. One contract worker was injured in the fire.

• The Texas City Refinery Explosion – Texas

  On March 23, 2005, a catastrophic explosion at the Texas City Refinery, owned by BP (British Petroleum), shocked the nation and resulted in significant loss of life and property. The explosion occurred when a hydrocarbon vapor cloud ignited, causing a massive blast that left 15 people dead and more than 180 others injured. The Texas City Refinery explosion ranks as one of the deadliest industrial accidents in U.S. history.

  The explosion was the result of a series of failures and safety lapses within the refinery, including inadequate maintenance, faulty equipment, and a flawed safety culture. Investigations revealed that several warning signs of a potential disaster had been ignored or overlooked. The explosion not only had devastating human consequences but also caused extensive damage to the facility and surrounding areas, with debris scattered over a wide radius. This tragic event prompted a reevaluation of safety practices within the petrochemical industry and emphasized the critical importance of proper maintenance, training, and oversight to prevent such disasters in the future.

• The West, Texas Fertilizer Plant Explosion – Texas

  On April 17, 2013, a devastating explosion at the West Fertilizer Co. in the rural town of West, Texas, left 15 people dead, over 200 injured, and hundreds of homes reduced to rubble. Federal investigators determined this tragic incident was the result of criminal activity.

  The force of the explosion was so immense that it registered as a magnitude-2.1 earthquake. A 93-foot-wide crater scarred the site of the fertilizer plant, where hazardous chemicals, including ammonium nitrate, were stored. The blast flattened the farming community, leaving around 2,800 residents in shock as their homes turned to rubble. Tragically, ten first responders and two volunteers were among those killed while battling the initial blaze.

• The Phillips K-Resin Plant Explosion – Texas

  On March 27, 2000, tragedy struck at Phillips Petroleum’s Houston Chemical Complex in Pasadena, Texas, when an explosion and fire at the K-Resin facility resulted in one fatality and 71 injuries. The explosion occurred in a tank undergoing cleaning. The tank lacked pressure and temperature gauges that could have alerted workers.

  Following a six-month investigation, the Occupational Safety and Health Administration (OSHA) attributed the explosion to a failure to train workers properly. OSHA proposed $2.5 million in penalties for 50 alleged safety standard violations at the facility. Rodney Gott, a supervisor who had previously survived the Phillips Disaster of 1989, tragically lost his life in the incident.

• The Imperial Sugar Refinery Explosion – Georgia

  On February 7, 2008, a sugar dust explosion at the Imperial Sugar refinery in Port Wentworth, Georgia, claimed 14 lives and left 38 people injured. The U.S. Chemical Safety Board’s report, released in September 2009, deemed the explosion “entirely preventable.”

  The explosion, fueled by a massive accumulation of combustible sugar dust, originated in the packaging facility at the center of the refinery. The blast caused extensive damage, turning the structure into a maze of twisted metal. The refinery’s fire suppression system was ineffective, leading to a challenging firefighting operation.

  The incident was not unforeseen, as dust explosions had contributed to fatal incidents just five years earlier. Understanding the dynamics of dust explosions is important, considering the broad range of industries susceptible to such disasters.

• The Dupont La Porte Chemical Facility Toxic Chemical Release – Texas

  On November 15, 2014, a tragic incident occurred at the DuPont La Porte Chemical Facility in La Porte, Texas, when 24,000 pounds of methyl mercaptan were unintentionally released from vent piping during startup and troubleshooting operations at an insecticide production plant. The release of methyl mercaptan proved fatal, taking the lives of four employees and causing injuries to two additional employees.

  The incident stemmed from a shutdown of the DuPont Lannate process on November 10, during which a portion of the methyl mercaptan piping in the reaction section became obstructed due to the formation of a solid hydrate. Over several days, plant personnel engaged in troubleshooting efforts and eventually identified and dislodged the plug using hot water on the outside of the piping. As part of the troubleshooting process, plant personnel opened valves from the mercaptan piping to the waste gas vent header to relieve pressure. Unfortunately, the vent header provided an open pathway into an interior building through drain lines, allowing the released methyl mercaptan liquids to enter the building. This incapacitated multiple plant personnel who were troubleshooting the issue and responding to alarms, leading to injuries and fatalities.

• The Kleen Energy Natural Gas Explosion – Connecticut

  On Sunday, February 7, 2010, a catastrophic natural gas explosion rocked the Kleen Energy power plant, which was under construction in Middletown, Connecticut, resulting in a tragic loss of six lives and leaving more than 50 individuals injured. The incident occurred during the commissioning and startup phase of the Kleen Energy project while workers were engaged in the planned cleaning of fuel gas piping. Specifically, they were conducting a procedure known as a “gas blow,” which involved forcing natural gas through the piping at high pressure and volume to remove debris. Unfortunately, during this process, the natural gas and debris were released directly into the atmosphere.

  The Kleen Energy construction site used natural gas at an approximate pressure of 650 pounds per square inch gauge (psig), and a total of 15 natural gas blows were performed intermittently over approximately four hours through open-ended pipes located less than 20 feet off the ground, adjacent to the south wall of the main power generation building.

• ConAgra Foods Plant Explosion – North Carolina

  On June 9, 2009, a tragic explosion occurred at the ConAgra Foods plant during the installation of an industrial water heater by a contractor from Energy Systems Analysts (ESA). The ESA worker attempted to purge air from a three-inch natural gas supply pipe for the heater, using natural gas for the process. As per ESA’s standard practices, the purged gases were vented into a utility room equipped with a ventilation fan. Struggling to light the heater, the workers continued purging the gas line for over two and a half hours. Plant personnel were aware of this indoor purging and relied on their sense of smell to detect any potential gas buildups.

  The explosion resulted in significant damage to approximately 100,000 square feet of the facility, mainly in the southern part where packing operations were conducted. The blast also triggered a leak from the plant’s refrigeration system, releasing approximately 18,000 pounds of ammonia.

  Tragically, four workers lost their lives, including a member of ConAgra’s safety team who heroically attempted to rescue a co-worker and was killed by falling debris. Additionally, 71 people were hospitalized with injuries, including three firefighters who were exposed to ammonia during the incident.

• The LyondellBasell La Porte Fatal Chemical Release – Texas

  On July 27, 2021, a tragic chemical release occurred at the LyondellBasell La Porte Complex in La Porte, Texas, resulting in the loss of two lives and injuries to several workers.

  Three contract workers employed by Turn2 Specialty Companies were tasked with removing an actuator from a plug valve within the site’s acetic acid unit to use the valve as an energy isolation device for a pipe spool repair job. During the process, the workers removed pressure-retaining components of the valve, causing the plug to be ejected from the valve body. This resulted in the sudden release of approximately 164,000 pounds of acetic acid mixture, spraying all three contract workers with the corrosive substance.

  Tragically, two of the workers suffered fatal injuries due to chemical burns and toxic inhalation resulting from exposure to acetic acid and methyl iodide. Additionally, the third Turn2 worker and a LyondellBasell responder sustained serious injuries, while 29 other personnel were transported to medical facilities for evaluation and treatment.

• D.D. Williamson & Co.Catastrophic Vessel Explosion – Kentucky

  A catastrophic explosion at D.D. Williamson & Co., Inc. claimed the life of one operator. The explosion damaged the facility’s western end, releasing 26,000 pounds of aqua ammonia. The explosion led to the evacuation of 26 residents and required 1,500 people to shelter in place.

• Chemical Explosion at First Chemical Corp. – Mississippi

  The First Chemical Corporation (FCC) facility in Pascagoula, Mississippi, exploded on October 13, 2002, caused by steam leaking through manual valves, inadvertently heating
  mononitrotoluene within a shutdown distillation column. With approximately 1,200 gallons of MNT present, decomposition occurred over several days, causing a runaway reaction and subsequent explosion. Debris from the blast ignited a fire in an MNT storage tank alongside multiple smaller fires both onsite and offsite.

• Kaltech Industries Explosion – New York

  The Kaltech Industries Group, Inc., a sign manufacturer, was responsible for an explosion in New York City. While consolidating hazardous waste from smaller containers into larger drums, an explosion and subsequent fire erupted, injuring at least 36 individuals, including citizens and
  six firefighters.

• Vapor Cloud Fire at BLSR Operating Ltd. – Texas

  The BLSR Operating, Ltd, facility in Rosharon, Texas, exploded on January 13, 2003, resulting in the death of two BLSR employees and serious burns to three others, including two Environmental Services Inc. truck drivers who had just completed a delivery. One of the truck drivers died from his injuries.

• DPC Enterprises Festus Chlorine Spill

  A chlorine gas leak from a railroad tank car owned by DPC Enterprises, caused over 48,000
  pounds of chlorine gas to leak into the air over three hours, resulting in the hospitalization of 63 members of the community.

• Third Coast Industries Facility Petroleum Fire  – Texas

  Third Coast Industries, a facility that specializes in blending and packaging various types of oils and lubricants, caught on fire on May 1, 2002. Since the building was not equipped with adequate fire prevention, despite the efforts of the firefighters, the fire could not be contained. The fire destroyed the facility, 1.2 million gallons of flammable liquids, and led to the evacuation of 100 residents.

• Georgia-Pacific Corp. Hydrogen Sulfide Leak – Alabama

  On January 16, 2002, a leak of hydrogen sulfide gas occurred at the Georgia-Pacific Naheola mill in Pennington, Alabama. Two contractors from Burkes Construction lost their lives, and eight others were injured.

• Motiva Enterprises Sulfuric Acid Tank Explosion – Delaware

  On July 17, 2001, an explosion occurred at Motiva Enterprises’s Delaware City Refinery in Delaware City, Delaware. The explosion happened while contractors were conducting repairs on a catwalk grating in a sulfuric acid storage tank farm. The explosion led to the death of Jeffrey Davis, a boilermaker working with WGI. The incident also resulted in injuries to eight
  other individuals.

• BP Amoco Thermal Breakdown Explosion – Georgia

  On March 13, 2001, a pressure explosion at BP Amoco Polymers in Augusta, Georgia, left three people dead. The pressure explosion happened when a partially loosened cover of a
  pressurized vessel was ejected, releasing hot plastic. This sudden release also caused nearby tubing to rupture, leading to the spillage of hot fluid which then ignited, resulting in a fire.

• Concept Sciences Hydroxylamine Explosion – Pennsylvania

  Concept Sciences chemical plant in Allentown, Pennsylvania, had a vessel containing a large amount of hydroxylamine, explode on February 19, 1999. The explosion happened while employees were conducting the first commercial distillation of an HA and potassium sulfate solution at CSI’s new facility. Following the completion of the distillation process, the HA underwent explosive decomposition, likely triggered by its high concentration and temperature
  within the process tank and pipes. The explosion resulted in the death of four CSI employees and a manager from a neighboring
  business. Additionally, two CSI employees suffered moderate to serious injuries but survived. The blast also injured four individuals in adjacent buildings, and during the emergency response, six firefighters and two security guards incurred minor injuries.

  The explosion resulted in the death of four CSI employees and a manager from a neighboring business. Additionally, two CSI employees sustained moderate to serious injuries but survived. The blast also injured four individuals in adjacent buildings, and during the emergency response, six firefighters and two security guards incurred minor injuries.

• Bethlehem Steel Corp. Gas Fire – Indiana

  Two people were killed and four people injured in the February 2, 2001 Bethlehem Steel Corporation’s mill fire in Chesterton, Indiana. The fire occurred when workers removed a slip blind from a cracked valve, allowing a flammable liquid to escape and catch fire. The incident claimed the lives of a millwright from Bethlehem Steel and a contractor supervisor.

• Tosco Avon Refinery Petroleum Naphtha Fire – California

  A naphtha-caused fire at Tosco Corporation’s Avon refinery in Martinez, California, killed four workers and seriously injured one. This fire was the result of Naphtha, a highly flammable chemical, leaking onto hot equipment. The fire engulfed five workers at various levels of the tower.