Pollution
Humain
Environnement
Economique

On 10 September 2013, two operators were concluding the filling phase of dimethyl carbonate into reactor R20 of unit RS1 from 200 litre sheet metal drums, using vacuum suction with flexible hose connected to the reactor for the loading phase, up to a total of 849 kg (four whole drums plus a residual fraction of a fifth drum placed on the scales). The product was transferred in an open cycle. When about 10-15 litres were left in the fourth barrel and the barrel was to be emptied completely, tipping the barrel to provide greater depth, and presumably in the subsequent phase of removal of the filling lance, the dimethyl carbonate vapours in the barrel itself ignited, causing the barrel to explode, the bottom to become detached and the consequent immediate ignition of all the product, with an impact area limited to the sampling point (around two metres). The first operator, who was responsible for handling the flammable products, was hit by burning dimethyl carbonate (presumably a flash fire) and sustained burns to much of his body. He subsequently died after around ten days of hospital treatment. The other operator, supporting the handling operations, fell to the ground a short distance away and suffered bruises and minor burns; he returned to work after 36 days of accident leave.

At the time of the incident, only the two operators were present in the area concerned. In the initial phase (a few minutes), the shift supervisor and other operators from the unit and the laboratory came running from the upper floor and the ground floor having been attracted by the noise created by the event. The laboratory operators carried out first aid. One of the operators from the quality laboratory responsible for communication proceeded to make the emergency call (112), the call to the health and safety manager and, subsequently, to other members of the management team. Two ambulances, the Carabinieri (police), the fire brigade, and a rapid response car from the local health authority thus attended the scene. The seriously injured operator was taken to a specialist burns unit. The other operator involved received hospital treatment and was then discharged. Following the events, company staff completed the interrupted operations, with the approval of the authorities present, for the sole purpose of making the reactor safe.

The first operator, who was responsible for handling the flammable products, was hit by burning dimethyl carbonate (presumably a flash fire) and sustained burns to much of his body. He subsequently died after around ten days of hospital treatment. The other operator, supporting the handling operations, fell to the ground a short distance away and suffered bruises and minor burns; having also reported psychological traumas, he returned to work after 36 days of accident leave. No damage to the buildings, equipment or materials present in the unit were recorded.

Dimethyl carbonate: liquid at room temperature, used as a reagent for synthesis. The substance is classified as: highly flammable liquid and vapour (R11 — H225). The quantity of the substance involved in the event is around 10 kg. The quantity potentially affected is around 200 kg.

The company acted quickly to implement and report, in its safety management system, a new version of the procedure for handling flammable substances, which is more explicit about chemical compatibility and earthing the system, and the proper identification of the specific equipment (BGB-ILS-008 rev. B of 16 September 2013, ‘Handling and use of flammable raw materials H225 H226 — R10 and R11 in RS1’). The company is currently looking into a new, fixed filling system for flammable raw materials, in a closed cycle and/or a nitrogen atmosphere, from mobile containers, so as to rule out the possibility of inappropriate operations. The Commission points out that the risk related to electrostatic charges when transferring products from small containers tends to be underestimated. In order to limit that risk, specific management measures are essential. It may also be worth considering using closed cycle transfer systems. It would be useful to look closely at these aspects in the context of assessments by the competent authorities and during inspections.