April 10, 2025

Burst of a phenolic resin reactor due to abnormal reaction

 Raw materials were charged into the reactor that manufactured dihydroxydiphenylmethane by a reaction of phenol with formaldehyde at night on the previous day. By putting in the catalyst in the morning of the day, the contents were heated to the fixed 80 °C, and heating was stopped. However, the temperature continued to rise, so cooling was attempted, but a runaway reaction occurred. As a result, the internal pressure of the reactor increased and the reactor burst. One operator was injured. Although the cause cannot be specified, it is supposed that the temperature was raised too high initially, agitation was started while the temperature was rising, and vapor pressure was increased because cooling water piping was blocked, and so on.

Read about the incident in this link

April 2, 2025

Safety Critical Task Analysis (SCTA)

"Human activities are involved in different aspect of operation of a chemical facility. Starting from design, construction, commissioning, operation, maintenance till decommissioning, human is involved. For safe and reliable operation, high human reliability is required in all phases of lifecycle of the facility. However human errors have contributed to many major industrial accidents in Chemical facilities in the past. Few examples are listed" in this link