Ruptured reboiler containing anhydrous Hydrogen Fluoride, Honeywell Geismar, Louisiana, 23rd Jan 2023
The reboiler catastrophically failed on January 23, 2023, during a startup of the 245 unit, which produces a refrigerant called HFC245a. The startup proceeded
normally, until a reboiler within the unit suddenly exploded, releasing over 800 pounds of anhydrous HF and over 1,600 pounds of toxic chlorine gas. The reboiler had thinned over time due to corrosion and the failure occurred under otherwise normal operating conditions.
The Honeywell Geismar site did not effectively manage the thinning reboiler shell. Although the site
had established acceptance criteria, inspected the reboiler, and successfully detected a deficiency prior
to failure, the site did not effectively communicate the issue to all appropriate stakeholders and did not
take all of its own prescribed actions for deficiency management. A capital replacement project was initiated to replace the thinning reboiler, but the Honeywell unit maintenance engineer left the company and the project was not reassigned. The issue essentially fell through the cracks of Honeywell's Management Of Organizational Change (MOOC) and the reboiler was run to failure.
No personnel were within the unit, and no injuries
resulted from the incident. Honeywell reported $4 million in property damage resulting from this incident, and a complex-wide shelter-in-place order was initiated at the facility, which included two neighboring manufacturing
companies. Local officials also temporarily closed nearby highways.
The incident was one of three anhydrous Hydrogen Fluoride toxic releases that led the CSB to investigate at the Honeywell Geismar plant, including a gasket failure that caused an operator fatality.
[Full CSB report](https://www.csb.gov/file.aspx?DocumentId=6295)