What is UCIL and which material was causing the health hazard in UCIL accident? What are the major causes of failures in VIZAG GAS Leak?

 UCIL (Union Carbide India Limited) was a pesticide manufacturing company in India, primarily known for the catastrophic chemical disaster that occurred at its plant in Bhopal, Madhya Pradesh, in December 1984. This disaster is considered one of the world's worst industrial accidents. UCIL was a subsidiary of the Union Carbide Corporation (UCC), which was headquartered in the United States.

The Bhopal Gas Tragedy and Hazardous Material

The health hazard in the UCIL accident was caused by the release of methyl isocyanate (MIC), a highly toxic and volatile chemical used as an intermediate in pesticide production. The uncontrolled release occurred on the night of December 2–3, 1984, when a storage tank containing MIC developed a leak due to a combination of safety system failures and human error.

Effects of Methyl Isocyanate:

• Acute Toxicity: MIC is highly toxic when inhaled, ingested, or contacted by skin. It affects the respiratory system, eyes, and skin, causing symptoms such as coughing, breathlessness, eye irritation, and skin burns.
• Long-Term Health Consequences: Survivors of the Bhopal disaster experienced chronic health issues, including respiratory problems, eye damage, neurological disorders, and reproductive complications. The accident claimed thousands of lives in the immediate aftermath, and many more died later due to exposure-related complications.

Causes of the UCIL Bhopal Disaster

The incident at UCIL was the result of multiple contributing factors, which can be categorized into technical failures, managerial oversights, and regulatory deficiencies:

1. Lack of Proper Safety Systems: Critical safety measures, such as the refrigeration unit meant to keep MIC at a low temperature, were not functioning at the time of the incident. This allowed the chemical to heat up, leading to increased pressure and the eventual leak.
2. Inadequate Maintenance: Essential equipment, including the scrubbers and flare tower designed to neutralize any leaked MIC, was either turned off or malfunctioning.
3. Design Flaws: The design of the MIC storage tanks did not meet adequate safety standards. The storage system allowed for large volumes of MIC to be stored in a single tank, increasing the risk of catastrophic failure.
4. Poor Safety Culture: The management's disregard for safety protocols and lack of training for the staff on emergency procedures significantly contributed to the scale of the disaster.
5. Cost-Cutting Measures: In an attempt to reduce expenses, essential safety and maintenance practices were neglected.

Major Causes of Failures in the Vizag Gas Leak (LG Polymers Plant)

The Vizag gas leak occurred on May 7, 2020, at the LG Polymers plant in Visakhapatnam, Andhra Pradesh, India. Styrene gas, a toxic substance used in the manufacture of polystyrene products, was released into the atmosphere, leading to fatalities and health impacts on thousands of people. The major causes of failures in the Vizag gas leak include:

1. Temperature Control Failure:

• The root cause of the gas leak was linked to a failure in the refrigeration system responsible for keeping the temperature of the styrene storage tank low. Styrene is stable when kept below 20°C; any increase in temperature can cause the chemical to polymerize and generate heat, leading to a rise in pressure and vapor release.
• The malfunctioning refrigeration unit failed to prevent temperature fluctuations, resulting in the formation of excess vapors that escaped the tank.

2. Aging Infrastructure:

• The LG Polymers plant had been operating for decades, and certain parts of its infrastructure were outdated. The lack of modernization or replacement of old equipment posed significant risks, as safety mechanisms were not up to current industry standards.

3. Inadequate Safety Protocols:

• The company did not have robust safety protocols or emergency response plans in place to handle potential gas leaks. The absence of an effective safety management system exacerbated the impact of the incident.
• There were reports that the plant lacked comprehensive alarm systems or real-time monitoring for gas leaks, which delayed the response to the emergency.

4. Lack of Proper Maintenance:

• Routine maintenance practices were either inadequate or overlooked, which contributed to the deterioration of essential safety equipment.
• The company reportedly did not perform regular checks or update procedures to maintain the integrity of the storage tanks.

5. Regulatory Oversight:

• Insufficient regulatory enforcement and oversight allowed the plant to operate with vulnerabilities that should have been addressed by periodic audits and compliance checks. Authorities had not effectively monitored safety practices or updated licenses and safety clearances.

6. Chemical Storage Issues:

• Styrene was stored in large quantities that exceeded the recommended safety limits. The lack of temperature control combined with the volume stored increased the risk of vapor release.

Conclusion

Both the UCIL Bhopal disaster and the Vizag gas leak underscore the importance of stringent safety measures, regular maintenance, and a culture that prioritizes the well-being of workers and the surrounding community. The UCIL incident involved methyl isocyanate, causing immediate and long-term health impacts, while the Vizag incident was due to the release of styrene gas, exacerbated by outdated infrastructure, inadequate safety practices, and failures in temperature regulation. These events highlight the critical need for comprehensive safety management systems and proactive regulatory oversight to prevent similar tragedies in the future.

Subscribe on YouTube - NotesWorld

For PDF copy of Solved Assignment

Any University Assignment Solution

WhatsApp - 9113311883 (Paid)