Bhopal union carbide process

Figure 1.4 Simplified flow chart of the Bhopal Union Carbide process.

Figure 1.5 Methyl isocyanate (MIC storage) tank used in the Bhopal Union Carbide process. Source adapted from Reference [31].

Figure 1.7 Schematic diagram of the emergency relief effluent treatment system that includes a scrubber and flare tower in series in the Bhopal Union Carbide process.

Therefore, awareness that influences willingness, and leadership, but also new forms of communication and cooperation and a possible shift in corporate (safety) culture, are all crucial elements for ISP. Good and successful examples set by companies seen as peers may also strongly stimulate industry. Indeed, the production of the same pesticide produced by Union Carbide in Bhopal using a batch process was accomplished by DuPont using an inherently safer continuous flow process. 

On December 3 and 4, 1985, a chemical release causing a massive toxic gas cloud occurred at the Union Carbide India, Ltd, plant in Bhopal, India. (Union Carbide is now a part of The Dow Chemical Company.) The process involved used methyl isocyanate (MIC), an extremely toxic chemical, to make Sevin, a pesticide. According to various authoritative reports, about 1,700-2,700 (possibly more) people were killed, 50,000 people were affected seriously, and 1,000,000 people were affected in some way. The final settlement may involve billions of dollars. It was one of the worst industrial accidents in history. The accident occurred when about 120-240 gallons of water were allowed to contaminate an MIC storage tank. The MIC hydrolyzed, causing heat and pressure, which in turn caused the tank rupture disk to burst. 

Many investors may erroneously take at face value the management s statements that the company acquired no liability for Bhopal and the company cites a number of issues and developments to back up this claim.53 However, Union Carbide remains a named accused in the criminal case in India, placing Dow Chemical assets in India at risk for potential attachment in the ongoing case. In addition, the Indian government is reportedly processing a request to sue Dow to engage in remediation of the site. 

In 1984, one of the most notable process incidents occurred in Bhopal, India, at a plant owned by Union Carbide. On December 3, 1984, methyl isocyanate (MIC) was vented to the atmosphere from a vent gas scrubber after a run away reaction overwhelmed the scrubber. It is reported that more than 2500 people died and 20,000 people were injured as a result of exposure to MIC. The subsequent investigation showed that the run away reaction occurred in the MIC tanks after water was reportedly intentionally added to the tank. The safety systems, a pressure relief valve, a vent gas scrubber, and a flare were reportedly poorly maintained. The relief valve worked to vent the pressure, but the scrubber was overwhelmed, and the flare was down for maintenance. This incident highlighted several loss prevention areas that needed improvement. The first was mechanical integrity. No strong preventive maintenance effort appeared to be in place. The second was emergency preparedness and response. It appears that while the plant was built 1.5 miles away from the community, zoning problems allowed the community to expand to the plant limits. It does not appear that much effort was made to work with the community on commimication/notification or evacuation needs. ... 

The Bhopal disaster (also referred to as the Bhopal gas tragedy) was a gas leak in Bhopal, India, that happened in December of 1984. At the Union Carbide plant in Bhopal, methyl isocyanate gas was accidentally released during a manufacturing process. The gas poisoned thousands of people in the surrounding city, most of... 

Union Carbide Bhopal, India Issues arising during a pipe washing procedure resulted in pressure rise and release of toxic gas from vent stack Est. 2,000 -10,000 fatalities unknown injuries Institutional knowledge not captured prior to downsizing employees performing unfamiliar tasks joint venture doesn t alleviate responsibility for process safety 4,6... 

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