Episode 80 - Incident Breakdown: 2020 Fatal Chemical Release at Wacker Polysilicon Facility in Tennessee

Amplify Your Process Safety

In this episode, Molly and Jo discuss the CSB's final investigation report on the 2020 fatal chemical release at Wacker Polysilicon facility in Charleston, Tennessee. On November 13, 2020, a contractor on the fifth level of an operating platform tightened the bolts on a graphite heat exchanger to an incorrect torque setting, cracking the exchanger, which released gaseous HCl and obscured two contractor groups' access down the 70-foot platform's only staircase. Three of the contractors attempted to climb down the outside of the structure, and all fell during their attempts; one fatally, while two others sustained serious injuries. Today, Molly and Jo provide some background information on the facility, its hazardous chemicals, and the events leading up to the loss of containment. Additionally, they discuss the safety issues identified by the CSB, including some interesting details regarding the PHA completed only three months prior that identified the need for a second means of egress in a release scenario identical to the incident. They point out other contributing factors, cover the CSB's various recommendations, and finally provide key learnings that any company can glean from this incident.

Find the CSB's final report for this incident ⁠⁠⁠here⁠⁠.