Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience Committee on Inherently Safer Chemical Processes: The Use of Methyl Isocyanate (MIC) at Bayer CropScience Board on Chemical Sciences and Technology Division on Earth and Life Studies THE NATIONAL ACADEMIES PRESS Washington, D.C. www.nap.edu Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience THE NATIONAL ACADEMIES PRESS 500 Fifth Street, NW Washington, DC 20001 NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competences and with regard for appropriate balance. This study was supported by the Chemical Safety and Hazard Investigation Board under Award No: TPD-CSB-1O-C-OOO1. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the authors and do not necessarily reflect the views of the organizations or agencies that provided support for the project. International Standard Book Number 13: 978-0-309-25543-1 International Standard Book Number 10: 0-309-25543-0 Cover image: Bayer CropScience. Additional copies of this report are available from the National Academies Press, 500 Fifth Street, NW, Keck 360, Washington, DC 20001; (800) 624-6242 or (202) 334-3313; http:// www.nap.edu. Copyright 2012 by the National Academy of Sciences. All rights reserved. Printed in the United States of America. Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a man- date that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Charles M. Vest is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examina- tion of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. Charles M. Vest are chair and vice chair, respectively, of the National Research Council. www.national-academies.org Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience COMMITTEE ON INHERENTLY SAFER CHEMICAL PROCESSES: THE USE OF METHYL ISOCYANATE (MIC) AT BAYER CROPSCIENCE Elsa REichmanis (Chair), Georgia Institute of Technology Paul amyottE, Dalhousie University PEtER BEak, University of Illinois at Urbana-Champaign michaEl l. P. Elliott, Georgia Institute of Technology WaynE B. GRay, Clark University DEnnis c. hEnDERshot, Independent Consultant anDREa kiDD tayloR, Morgan State University michaEl k. linDEll, Texas A&M University JacquElinE macDonalD GiBson, University of North Carolina at Chapel Hill JEffERy J. siiRola, Eastman Chemical Company (retired) John soREnsEn, Oak Ridge National Laboratory (resigned from committee on 2/28/2011) National Research Council Staff kathRyn huGhEs, Study Director DoRothy ZolanDZ, Director JEffREy JacoBs, Director, Water Science and Technology Board ERicka mcGoWan, Program Officer (until April 2011) shEEna siDDiqui, Senior Program Associate amanDa clinE, Administrative Assistant RachEl yancEy, Senior Program Assistant v Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience vi BOARD ON CHEMICAL SCIENCES AND TECHNOLOGY PaBlo DEBEnEDEtti (Co-Chair), Princeton University c. DalE PoultER (Co-Chair), University of Utah, Salt Lake City ZhEnan Bao, Stanford University RoBERt G. BERGman, University of California, Berkeley hEnRy E. BRynDZa, E. I. du Pont de Nemours & Company Emily caRtER, Princeton University DaviD chRistianson, University of Pennsylvania maRy JanE haGEnson, Chevron Phillips Chemical Company LLC caRol J. hEnRy, The George Washington University Jill hRuBy, Sandia National Laboratories michaEl kERBy, ExxonMobil Chemical chaRlEs E. kolB, Aerodyne Research, Inc. JosEf michl, University of Colorado, Boulder sanDER G. mills, Merck, Sharp, & Dohme Corporation DaviD moRsE, Corning Inc. RoBERt E. RoBERts, Institute for Defense Analyses DaRlEnE J. solomon, Agilent Technologies JEan tom, Bristol-Myers Squibb DaviD Walt, Tufts University National Research Council Staff DoRothy ZolanDZ, Director kathRyn huGhEs, Program Officer tina m. mascianGioli, Senior Program Officer DouGlas fRiEDman, Program Officer amanDa clinE, Administrative Assistant shEEna siDDiqui, Senior Program Associate RachEl yancEy, Senior Program Assistant Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience vii The Committee on Inherently Safer Chemical Processes: The Use of Methyl Isocyanate (MIC) At Bayer CropScience would like to thank the many technical, chemical, and engineering experts who contributed to the integrity of this report through the submission of informative materials and attendance of committee meetings. The committee would like to acknowledge Amy McCormick and Lucy Sciallo-Tyler of the U.S. Chemical Safety and Hazard Investigation Board; Steven Smythe, Patrick Ragan, Connie Stewart, Cindi Lester, Walter Martin, and the staff of the Bayer CropScience facility in Institute, West Virginia; Scott Berger, Center for Chemical Process Safety; Randall Sawyer, Contra Costa County; George Famini and George Emmett, Department of Homeland Security Analysis Center; John Carberry, Carberry EnviroTech; Matthew Blackwood and Larry Zuspan, Kanawha Putman Emergency Planning Committee; Craig Mattheisson, U.S. Environmental Protection Agency; and Warren Woomer of Charleston, South Carolina. We would also like to thank West Virginia State University in Institute, West Virginia for hosting the committee members and National Research Council staff for an open public comment session. Our thanks to all those who participated in the comment periods and who contributed information in support of the com- mittee’s data-gathering efforts. Acknowledgments Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience This report has been reviewed in draft form by persons chosen for their diverse perspectives and technical expertise in accordance with procedures approved by the National Research Council’s Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making the published report as sound as possible and to ensure that it meets institutional standards of objectivity, evidence, and responsiveness to the study charge. The review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following for their review of this report: DaniEl a. cRoWl, Michigan Technological University chau-chyun chEn, AspenTech maRtin shERWin, W.R. Grace & Company, Retired John saWyER, MATRIC Research michaEl WRiGht, United Steel, Paper and Forestry, Rubber, Manufacturing, Energy, Allied Industrial and Service Workers International Union (United Steelworkers) scott faRRoW, UMBC Gail BinGham, RESOLVE nED hEinDEl, Lehigh University michaEl R. hoffman, California Institute of Technology Pam nixon, West Virginia Department of Environmental Protection may BEREnBaum, University of Illinois at Urbana-Champaign John h. soREnsEn, Oak Ridge National Laboratory (retired) ix Acknowledgment of Reviewers [...]... 13 Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience 14 USE AND STORAGE OF METHYL ISOCYANATE (MIC) AT BAYER CROPSCIENCE carbamate pesticides; and (3) examine the use and storage of MIC at the Bayer CropScience facility in Institute, West Virginia The third part of the task was the most complex, containing the following subparts:... investigation by the U.S Chemical Safety and Hazard Investigation Board found that the debris could have struck a relief valve vent pipe and caused the release of MIC to the atmosphere The Board’s investigation also highlighted 1 Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience 2 USE AND STORAGE OF METHYL ISOCYANATE (MIC) AT BAYER. .. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience Summary The use of hazardous chemicals such as methyl isocyanate can be a significant concern to the residents of communities adjacent to chemical facilities, but is often an integral, necessary part of. .. industry The use of these techniques m could benefit not only the communities at risk from safety breaches, but also the Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience 8 USE AND STORAGE OF METHYL ISOCYANATE (MIC) AT BAYER CROPSCIENCE BOX 4 Alternative Methods for Producing MIC and Carbamate Pesticides The report’s authoring... that it would “reduce methyl isocyanate (MIC) storage by 80 percent” at the facility and eliminate aboveground storage of MIC The company stated that it would cease production of MIC-based products within a year, and that it would Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience 23 INTRODUCTION “continue to evaluate the. .. Storage of Methyl Isocyanate (MIC) at Bayer CropScience Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience Technical Summary In 2008, an explosion and fire at a chemical production plant owned by Bayer CropScience (Bayer) in Institute, West Virginia resulted in the deaths of two employees and renewed attention to the onsite... upon the expertise within the committee membership as well as that of the publications from the Center for Chemical Process Safety, the Department of Homeland Security, and other material available in the literature, the following findings, conclusions, and recommendation were developed Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer. .. National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience 20 USE AND STORAGE OF METHYL ISOCYANATE (MIC) AT BAYER CROPSCIENCE To assist the chemistry community in addressing the last of these findings, which as mentioned above has been noted as a barrier to performing inherently safer process assessments, the committee highlighted a method of. .. Copyright © National Academy of Sciences All rights reserved The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience 22 USE AND STORAGE OF METHYL ISOCYANATE (MIC) AT BAYER CROPSCIENCE day tank, the shield structure might have impacted the relief valve vent pipe A puncture or tear in the vent pipe or MIC day tank head would have released MIC vapor into the atmosphere above the day tank.”... its state and federal regulators on how to reduce the dangers posed by onsite storage of MIC; and 4 Brief our staff on the Board’s findings and recommendations at the end of its investigation.” As a result of this request, the 111th Congress provided funds to the CSB “for a study by the National Academy of Sciences [NAS] to examine the use and storage of methyl isocyanate including the feasibility of . reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience 4 USE AND STORAGE OF METHYL ISOCYANATE (MIC) AT BAYER CROPSCIENCE inate a fire hazard, rather than accepting the existence. Storage of Methyl Isocyanate (MIC) at Bayer CropScience Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience The use of. reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience Copyright © National Academy of Sciences. All rights reserved. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience