Union Carbide Bhopal toxic gas release

On December 3, 1984, a toxic gas release from a pesticide plant in India killed nearly 3000 people and injured at least 100,000 others. The chemical that leaked was methyl isocyanate, a chemical intermediate that was supposed to be stored in a cooled bunker near the plant s outer boundary. The vapor is highly toxic and causes cellular asphyxiation and rapid death. Despite engineering and procedural provisions to prevent its release, a total system breakdown resulted in the release of 40 tons of the deadly material into the densely populated community of Bhopal. Because of this incident, the plant was dismantled and ultimately the parent corporation. Union Carbide, was forced to make a number of organizational changes. The occurrence is considered by many to have been the most tragic chemical accident in history. 

Methyl isocyanate (MIC) is a colorless liquid that must be stored in a cooled enclosure before it is subsequently used in the manufacture of carbamate, a common insecticide. MIC liquid is highly reactive in the presence of water and iron oxide, and it generates heat. In sufficient quantities, this heat may generate vapor, which, as explained previously, is highly toxic. Three adjacent bunkers were used for MIC storage. These were mounted in a berm and a refrigeration coil was used to ensure that the temperature did not exceed 5°C. A vent gas scrubber was used to prevent vapor escape, and despite a low operating pressure, a closed relief 

For several months before the accident, conditions at the plant had been deteriorating. Procedures were not carefully followed and several mechanical features were either shutdown or compromised. Examples include the refrigeration circuit that was depleted of coolant and the vent gas scrubber that was out of service. The temperature indicator on one tank was defective. The temperature in one of the tanks had been allowed to exceed the maximum limit by as much as 15°C with no corrective action. 

On the night of the accident, operators heard a screeching noise from the relief valve on one of the tanks. Unfortunately, the closed blowdown system had been taken out of service for maintenance. It was later established that while operators were on their shift change or on a break, someone disconnected a pressure gauge from the cover plate on one of the tanks and attached a water hose. A quantity of water estimated between 450 and 900 kg entered the tank and caused a severe upset and release of MIC vapor. With no means of notifying the public and evacuating the community, thousands were exposed to the vapor cloud, resulting in the deaths and injuries. 

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