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Synthron Explosion
Synthron Explosion
Synthron Explosion
SYNTHRON EXPLOSION
Case Study: Runaway Chemical Reaction and Vapor
Cloud Explosion
Linh Dinh
Maryy Kay
y O’ Connor Process Safety
y Center
Presentation to
Steering Committee
February 12th 2009
1
Background Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
Company profile
• Synthron Inc
Inc. plant
• Location: Morganton, North Carolina
• Produce acrylic polymers
Reaction overview
• Free radical polymerization in various flammable
solvents: Acrylic monomers Æ Acrylic polymers
Jan 31, 2006, the explosion occurred
• In a 1,500 gallon reactor
• At 75 psig maximum operating pressure
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Background Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
• Facility layout
http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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January 31, 2006 Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
Operating procedure
• Monomer and solvent: transferred
to reactor
• Heat the mixture using steam
• Add the initiator solution
On that day …
• Recipe: scaled up 12 %
• Additional monomer: added into
Figure 2
2. The polymerization reactor the initial charge
http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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A critical mistake Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
Total of monomer 45 %
Monomer concentration 27%
Atmospheric boiling point
temperature of the mixture
5°C (9°F).
I ff ti control
Ineffective t l off product
d t recipe
i changes
h
Modified recipe
Standard
recipe
Fi
Figure 2
2. R
Results
lt off reaction
ti calorimetry
l i t (by (b CSB iinvestigators)
ti t )
Reduce condenser
capacity
p y at least 25%
http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
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Contributing factors Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
http://www.csb.gov/completed_investigations/docs/Synthron%20Final%20Report.pdf
9
Lessons Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
Control changes
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10
Lessons Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
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Acknowledgement Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
Dr. Mannan
Dr. Rogers
All of members of MKOPSC
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Mary Kay O’Connor Process Safety Center
Making Safety Second Nature
THANK YOU
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