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Case Study Board Voting Copy February 2013 Carbide Industries Case Study Board Voting Copy February 2013 Case Study U.S. Chemical Safety and Hazard Investigation Board Carbide Industries, LLC, Louisville, KY Electric Arc Furnace Explosion March 21, 2011 2 Killed, 2 Injured No. 2011-05-I-KY KEY ISSUES • Facility Siting • Normalization of Deviance • Consensus Standards INSIDE • Process Discussion • Incident Description • Emergency Response • Analysis • Key Findings • Recommendations On March 21, 2011, during calcium carbide production at the Carbide Industries plant in Louisville, KY, an electric arc furnace exploded, ejecting solid and powdered debris, flammable gases, and molten calcium carbide at temperatures near 3800°F (2100°C). Two workers died and two others were injured. CSB • Carbide Industries Case Study 1 Carbide Industries Case Study Board Voting Copy February 2013 TABLE OF CONTENTS 1.0 Introduction 2 2.0 Process Discussion 3 3.0 Emergency Planning and Response 6 4.0 Incident Description 7 5.0 Analysis 8 6.0 Key Findings 13 7.0 Recommendations 14 8.0 References 15 9.0 Appendix A: Simplified Diagram of Calcium Carbide process 16 FIGURE 1 1.0 INTRODUCTION Satellite view of the Carbide Industries Louisville facility, Two workers were killed and two were injured at the Carbide Industries, LLC facility in with furnace building circled Louisville, KY, on Monday, March 21, 2011, when an electric arc furnace (EAF) overpres- sured and emitted powdered debris, hot gases, and molten calcium carbide. The hot gases and debris blown from the furnace broke through the double-pane reinforced glass window of the control room, severely burning the two workers inside; they died within 24 hours from burn injuries. Carbide Industries, LLC is the larger of two North American producers of calcium carbide and supplies calcium carbide primarily to the iron and steel industry and to acetylene1 producers. The main Carbide Industries facility is adjacent to the Ohio River in the “Rubbertown” section of western Louisville, KY. The company employs about 160 workers in operations, maintenance, and administration. The Louisville site operated one 50-mega- watt (MW) EAF with the capacity to produce 120,000 tons of molten calcium carbide per year. After draining the calcium carbide from the EAF and cooling it to a solid, the site grinds and packages the solid into multiple grades of calcium carbide for sale. Although the facility maintains an acetylene storage tank to collect fugitive acetylene gas from the calcium carbide plant, the operation does not produce acetylene gas to sell.2 1Adding water to calcium carbide produces acetylene gas and calcium hydroxide (lime). The acetylene gas is then purified to sell as welding gas and raw material for producing other chemicals. 2Carbide Industries burns the collected acetylene gas in a flare. CSB • Carbide Industries Case Study 2 Carbide Industries Case Study Board Voting Copy February 2013 Only a few calcium carbide industry facilities operate in the United States. In addition to the Carbide Industries facility in Kentucky, Central Carbide Corporation in Pryor, OK, operates a 17-MW electric arc furnace. Central Carbide Corporation is under the same ownership as Carbide Industries, LLC. Although the majority of EAFs used in the U.S. are for steel manufacturing,3 similar chemical producing operations use EAFs in the ferrosilicon, silicon, and phosphorus industries. 2.0 PROCESS DISCUSSION 2.1. CHEMICAL PROPERTIES OF CALCIUM CARBIDE Pure calcium carbide (chemical formula CaC2) consists of two carbon atoms and one calcium atom; it melts at about 3500°F (1926°C). At room temperature, commercially produced calcium carbide is a gray to black solid that is typically supplied as granules or powder con- taining about 75 to 85 weight percent calcium carbide with 15 to 25 weight percent calcium oxide and other impurities. Calcium carbide reacts with water, such as the humidity in air or the moisture in human tissues, to form acetylene gas (chemical formula C2H2) and calcium hydroxide (chemical formula Ca(OH)2). Acetylene is an extremely flammable gas. Calcium hydroxide is a caustic solid that can irritate the skin and eyes on contact and can lead to severe respiratory irritation and acute pulmonary edema when inhaled. 2.2. ELECTRIC ARC FURNACES FOR CALCIUM CARBIDE An EAF passes electricity through the air above a material to heat that material (indirect arc furnaces) and in some designs through the material as well (open arc and submerged arc furnaces). The electricity enters the EAF through large conductors called electrodes. Calcium carbide is manufactured in submerged arc EAFs through which electrodes protrude into the material to be heated. Radiative heating occurs from the arc in the air around the material, direct electrical resistance heating occurs as the electricity passes through the material, and convective heating occurs as the hot gases formed in the arc percolate through the material. EAFs can generate temperatures in the thousands of degrees centigrade. The calcium carbide process feeds coke4 pre-mixed with lime chunks (calcium oxide, (CaO)) to the EAF, and the electrodes protrude through the furnace cover into the pile of coke and lime. As the EAF provides electricity, heating the feed material to temperatures above 4100°F, the carbon in the coke reacts with the lime at high temperature to form liquid calcium carbide as a product and the toxic and flammable by-product carbon monoxide: ∆ CaO + 3C → CaC2 + CO Lime + carbon + heat → calcium carbide + carbon monoxide Since the coke contains some hydrogen atoms, the process also releases extremely flammable hydrogen gas (H2). 3According to the EPA, in 1999, there were 200 EAFs operated in US industry, 130 of which were used for steelmaking. 4Coke, a solid carbon that contains some hydrogen, is a black solid produced by high-temperature processing of high boiling petroleum- or coal-based process streams and residues in an oxygen-free environment. CSB • Carbide Industries Case Study 3 Carbide Industries Case Study Board Voting Copy February 2013 FIGURE 2 2.3 EQUIPMENT DESCRIPTION Cutaway view of the EAF The EAF at Carbide Industries was located on the ground floor of the five-story furnace building and location building (Figure 2). Due to the height of the furnace itself, the cover of the furnace was at the of victims at time of second floor level; the same level as the control room where the furnace operator controlled incident the chemical and electrical feeds to the furnace. The control room had a window made of dual-paned, one-half-inch thick, wire-reinforced glass. Figure 3 shows that the control room window was about 12 feet from the furnace cover. The furnace was a refractory-lined metal tank with three holes in the sidewall to drain the molten calcium carbide product. These three-hole positions were at the elevation of the mezzanine level, between the second and ground floor. The furnace cover was about four feet tall and made of refractory-lined metal that was water cooled. The refractory prevented the high-temperature materials in the furnace from contacting and melting the metal tank and cover. The furnace cover was fabricated in several sections and bolted together. Cooling water flowed through each hollow section as additional protection against overheating. Three electrodes protruded through the furnace cover. The electrodes extended from the fifth floor down to just below the second floor. Three transformers on the third floor supplied AC power to the electrodes. Location of victims CSB • Carbide Industries Case Study 4 Carbide Industries Case Study Board Voting Copy February 2013 FIGURE 3 Second floor of the furnace building and location of victims at the time of the incident Location of victims Tanks on the fourth level held pre-mixed feed until a conveyor system dispensed the material into chutes that distributed the feed around the furnace electrodes. The feed material flowed down into the furnace through the gaps between the electrode sheaths and the holes that the electrodes passed through in the furnace cover. 2.4. PROCESS DESCRIPTION The plant receives truck and rail deliveries of coke and lime respectively (Appendix A). An oven dries the coke and a weighing system mixes the coke with the lime in the desired weight ratio to feed the furnace. A system of tanks and chutes distributes the solid feed mixture (coke and lime) through the EAF cover and around the three electrodes. The furnace contains hot feed material, liquid calcium carbide, and flammable and toxic gases that are byproducts of the EAF, including hydrogen and carbon monoxide. The feed material falls through the feed chutes into the furnace and floats on the surface of the liquid calcium carbide, forming deep piles around each electrode. The furnace runs under slight pressure to prevent air from being drawn into the furnace and igniting the flammable gases. The gases produced in the furnace exit primarily through a vent system to a wet scrubber, a device that removes pollutants from gas through contact with liquid. Some of the gas exits into the second floor of the furnace building through the gaps between the electrode sheaths and the holes that the electrodes pass through in the furnace cover. In addition to monitoring electricity consumption, electrode consumption, CSB • Carbide Industries Case Study 5 Carbide Industries Case Study Board Voting Copy February 2013 and flowrates, workers look through the control room window to judge the process perfor- mance by the appearance (volume, color, and motion) of the flames that the process gases create when they exit the furnace and auto-ignite on contact with the room air. Cooling wa- ter exits the hollow furnace cover sections and returns to a trough before being recirculated. Molten calcium carbide exits the EAF at about 3800°F through the drain holes in the sidewall of the furnace.
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