We'll show you what ioMosaic can do to improve process safety in your organization.
A versatile tool for risk analysis, facility siting, PRFS evaluation and design, and more
Simplify the recording of findings and tracking of follow-up from PHAs
Browse training, attend courses, and get certified anytime and anywhere with our easy to use LMS
Boost your process safety with a 24/7 on-demand digital video streaming platform
Maximize your process safety management program with a PSM toolbox
Manage your critical process safety management data in one integrated platform
View the Newsletter
A butyl acrylate runaway reaction and subsequent vapor cloud explosion occurred at a facility located in Morganton, North Carolina, on January 31, 2006. The runaway reaction incident resulted in one death and multiple injuries and later led to the bankruptcy of the company. The incident was caused in part by the erroneous scale-up of the original reaction process recipe.
In this newsletter, Georges Melhem, Ph.D., FAIChE, and James Close,CEng, MIChemE, use Process Safety Office® SuperChems® Expert software to model the runaway reaction scenario and to examine the impact of the inhibitor on the thermal stability of butyl acrylate. Topics include:
Loss and excessive use of inhibitor are two scenarios that require evaluation for reactive monomer storage and pressure relief evaluation. Thermal stability information, including time to maximum rate, temperature of no return, and self acceleration reaction temperature, should be established.
Measurements using small scale calorimetry testing coupled with practical dynamic modeling using Process Safety Office® SuperChems® Expert or other suitable tools can provide a wealth of process and safety-critical data and information. This information is required for PSM-regulated chemical facilities in order to establish proper safe operating limits as required by the Process Safety Information (PSI) element.
Bonus! This newsletter also includes access to the video, Runaway: Explosion at T2 Laboratories, a 9-minute video from the U.S. Chemical Safety and Hazard Investigation Board with important lessons learned on chemical reactivity hazards. Specialty chemical companies, contract developers, manufacturing organizations, and toll manufacturers will find this particularly helpful.
Manufacturers with operations involving reactive chemistry can learn valuable lessons from this fatal incident.
Have a great and safe day.
Mar 3-5, 2026
Mar 4-5, 2026
Apr 12-16, 2026