Offline Butadiene Tank May Have Sparked Phillips K-Resin Explosion

A Phillips investigation team, mobilized to help determine what caused the tragic incident at the company's K-Resin plant within its Houston Chemical Complex (HCC) on March 27, has been focusing on a storage tank which had been taken off line and may have played a role in the incident.

"The most plausible scenario at this point is that a dry butadiene tank—taken offline, believed to be empty and in a purge mode—had sufficient 'popcorn' polymer and butadiene in the tank to react," says Jim Ross, General Manager of HCC. "We also believe the popcorn polymer plugged the purge lines so that an effective purge was not taking place. Under those circumstances, it appears that a reaction of residual popcorn polymer and butadiene could provide enough heat to overpressure the vessel, resulting in vessel failure."

The investigation into the incident at the K-Resin plant will not be complete until a review and analysis of the tank, residues and blast damage can be accomplished. However, these preliminary findings have been shared with the Occupational, Health & Safety Administration (OSHA), which is also conducting an investigation. "We are working closely with the investigating agencies, local officials, union leadership and our employees to fully understand exactly what happened and take corrective actions," says Ross.

The company continues to offer a range of assistance to employees, contractors, family members and others. "Our primary concern is for the well-being of those who were affected by the incident," says Ross. "We are continuing to provide support in the form of financial assistance, counseling, communications and, where needed, temporary accommodations for family members of those who remain in the hospital."

Of the 69 people who received medical attention, four Phillips employees and one contract worker remain hospitalized and all are listed in stable condition.

The Phillips investigation team, which was deployed immediately following the incident, consists of corporate personnel, representatives from HCC's unions (PACE and IBEW), its contractors, Brock and Zachry, and ECRC, a firm specializing in safety audits and services. The team has also retained the services of Wilfred Baker Engineering, Inc., of San Antonio, TX, which specializes in industrial incidents.

"We remain absolutely committed to operating this facility safely," says Ross. "We will not restart the K-Resin plant until we are certain that it is safe to do so. To that end, we have intensified our efforts to review our equipment, procedures and processes, working closely with third party experts and government authorities to thoroughly scrutinze our operations."

Edited by Wendy Reynolds