Chemical Manufacturing Incidents¶
Chemical manufacturing spans a vast range of processes — reactive chemistry, high-pressure synthesis, toxic intermediates, and thermally unstable materials — each with distinct hazard profiles that demand robust process safety management. CSB investigations in this sector document explosions, toxic releases, and runaway reactions at facilities ranging from small specialty chemical plants to large industrial complexes.
58 CSB investigations in this database cover the chemical manufacturing sector, spanning 1998–2024.
Chemical Manufacturing Incidents (58)¶
| Incident | Date | Location | Key Hazards |
|---|---|---|---|
| T2 Laboratories Inc. Reactive Chemical Explosion | 12/19/2007 | Jacksonville, FL | Runaway Reaction, Thermal Runaway |
| Environmental Enterprises Hydrogen Sulfide Release | 12/11/2002 | Cincinnati, OH | Hydrogen Sulfide Release, Toxic Release |
| Optima Belle Explosion and Fire | 12/08/2020 | Belle, WV | Explosion, Fire |
| NDK Crystal Inc. Explosion with Offsite Fatality | 12/07/2009 | Belvidere, IL | Explosion, Overpressure |
| Marcus Oil and Chemical Tank Explosion | 12/03/2004 | Houston, TX | Explosion, Fire |
| TPC Port Neches Explosions and Fire | 11/27/2019 | Port Neches, TX | Chemical Release, Explosion |
| CAI / Arnel Chemical Plant Explosion | 11/22/2006 | Danvers, MA | Explosion, Fire |
| DPC Enterprises Glendale Chlorine Release | 11/17/2003 | Glendale, AZ | Toxic Release, Chemical Release |
| DuPont La Porte Facility Toxic Chemical Release | 11/15/2014 | La Porte, TX | Toxic Release, Chemical Release |
| Wacker Polysilicon Chemical Release | 11/13/2020 | Charleston, TN | Chemical Release, Toxic Release |
| E. I. DuPont De Nemours Co. Fatal Hotwork Explosion | 11/09/2010 | Buffalo, NY | Explosion, Fire |
| Barton Solvents Flammable Liquid Explosion and Fire | 10/29/2007 | Des Moines, IA | Fire, Explosion |
| First Chemical Corp. Reactive Chemical Explosion | 10/13/2002 | Pascgoula, MS | Runaway Reaction, Explosion |
| INDSPEC Chemical Corporation Oleum Release | 10/11/2008 | Petrolia, PA | Chemical Release, Toxic Release |
| US Ink Fire | 10/09/2012 | East Rutherford , NJ | Dust Explosion, Flash Fire |
| Formosa Plastics Propylene Explosion | 10/06/2005 | Point Comfort, TX | Chemical Release, Explosion |
| EQ Hazardous Waste Plant Explosions and Fire | 10/05/2006 | Apex, NC | Fire, Explosion |
| Isotec/Sigma Aldrich Nitric Oxide Explosion | 09/21/2003 | Miami Township, OH | Explosion, Chemical Release |
| Bio Lab Conyers Chemical Release | 09/14/2020 | Conyers, GA | Thermal Runaway, Toxic Release |
| Arkema Inc. Chemical Plant Fire | 08/29/2017 | Crosby, TX | Fire, Chemical Release |
| AirGas Facility Fatal Explosion | 08/28/2016 | Pensacola, FL | Explosion, Runaway Reaction |
| Bayer CropScience Pesticide Waste Tank Explosion | 08/28/2008 | Institute, WV | Runaway Reaction, Explosion |
| Bio-Lab Lake Charles Chemical Fire and Release | 08/27/2020 | Lake Charles, LA | Runaway Reaction, Toxic Release |
| Sterigenics Ethylene Oxide Explosion | 08/19/2004 | Ontario, CA | Explosion, Fire |
| DPC Enterprises Festus Chlorine Release | 08/14/2002 | Festus, MO | Chemical Release, Toxic Release |
| LyondellBasell La Porte Fatal Chemical Release | 07/27/2021 | La Porte, TX | Chemical Release, Toxic Release |
| Honeywell Chemical Incidents | 07/20/2003 | Baton Rouge, LA | Chemical Release, Toxic Release |
| Barton Solvents Explosions and Fire | 07/17/2007 | Valley Center, KS | Explosion, Fire |
| Motiva Enterprises Sulfuric Acid Tank Explosion | 07/17/2001 | Delaware City, DE | Explosion, Fire |
| Dow Louisiana Operations Explosions | 07/14/2023 | Plaquemine, LA | Explosion, Fire |
| Praxair Flammable Gas Cylinder Fire | 06/24/2005 | St. Louis, MO | Fire, Explosion |
| Universal Form Clamp Co. Explosion and Fire | 06/14/2006 | Bellwood, IL | Vapor Cloud Explosion, Fire |
| Williams Olefins Plant Explosion and Fire | 06/13/2013 | Geismar, LA | Bleve, Chemical Release |
| Goodyear Heat Exchanger Rupture | 06/11/2008 | Houston, TX | Overpressure, Chemical Release |
| TS USA Molten Salt Eruption | 05/30/2024 | — | Explosion, Overpressure |
| Midland Resource Recovery Explosion | 05/24/2017 | Barbour County, WV | Explosion, Runaway Reaction |
| Kuraray Pasadena Release and Fire | 05/19/2018 | Pasadena, TX | Chemical Release, Fire |
| Veolia Environmental Services Flammable Vapor Explosion and Fire | 05/04/2009 | West Carrollton, OH | Explosion, Fire |
| AB Specialty Silicones, LLC | 05/03/2019 | Waukegan, IL | Chemical Release, Explosion |
| Third Coast Industries Petroleum Products Facility Fire | 05/01/2002 | Brazoria County, TX | Fire, Pool Fire |
| Formosa Plastics Vinyl Chloride Explosion | 04/23/2004 | Illiopolis, IL | Explosion, Fire |
| MFG Chemical Inc. Toxic Gas Release | 04/12/2004 | Dalton, GA | Runaway Reaction, Toxic Release |
| D.D. Williamson & Co. Catastrophic Vessel Failure | 04/11/2003 | Louisville, KY | Overpressure, Explosion |
| Yenkin-Majestic Resin Plant Vapor Cloud Explosion and Fire | 04/08/2021 | Columbus, OH | Vapor Cloud Explosion, Explosion |
| Morton International Inc. Runaway Chemical Reaction | 04/08/1998 | Patterson, NJ | Runaway Reaction, Thermal Runaway |
| KMCO LLC Fatal Fire and Explosion | 04/02/2019 | Crosby, TX | Vapor Cloud Explosion, Flash Fire |
| Union Carbide Corp. Nitrogen Asphyxiation Incident | 03/27/1998 | Hahnville, LA | Asphyxiation, Toxic Release |
| Carbide Industries Fire and Explosion | 03/21/2011 | Louisville, KY | Explosion, Overpressure |
| BP Amoco Thermal Decomposition Incident | 03/13/2001 | Augusta, GA | Chemical Release, Explosion |
| Concept Sciences Hydroxylamine Explosion | 02/19/1999 | Allentown, PA | Explosion, Chemical Release |
| Technic Inc. Ventilation System Explosion | 02/07/2003 | Cranston, RI | Explosion, Fire |
| Synthron Chemical Explosion | 01/31/2006 | Morganton, NC | Runaway Reaction, Vapor Cloud Explosion |
| Honeywell Geismar Chlorine and Hydrogen Fluoride Releases | 01/23/2023 | Geismar, LA | Chemical Release, Explosion |
| DuPont Belle Toxic Chemical Releases | 01/23/2010 | Belle, WV | Toxic Release, Chemical Release |
| Freedom Industries Chemical Release | 01/09/2014 | Charleston, WV | Chemical Release, Toxic Release |
| Texas Tech University Chemistry Lab Explosion | 01/07/2010 | Lubbock, TX | Explosion, Runaway Reaction |
| Sierra Chemical Co. High Explosives Accident | 01/07/1998 | Mustang, NV | Explosion, Fire |
| Catalyst Systems Inc. Reactive Chemical Explosion | 01/02/2003 | Gnadenhutten, OH | Explosion, Fire |
Frequently Involved Hazard Types¶
Chemical Release · Explosion · Fire · Toxic Release · Structural Failure · Overpressure
Most Common Chemicals Involved¶
Flammable Liquid, Toxic Gas, Hydrocarbon Vapor, Flammable Gas, Nitrogen, Chlorine
Data sourced from CSB.gov public investigation reports. This site is an independent project not affiliated with the U.S. CSB.