Explosion at Honeywell Plant Occurred Two Years After Replacement Recommendation, CSB Reports

Management approved the project but did not purchase or install a replacement shell before the Jan. 23, 2023, explosion.

By Jonathan Katz

July 22, 2024

2 min read

Honeywell's automotive refrigerants plant in Geismar, Louisiana.

A reboiler explosion at Honeywell's Geismar, Louisiana, facility in 2023 occurred about two years following a recommendation to replace the equipment due to its limited remaining lifespan, the U.S. Chemical Safety and Hazard Investigation Board (CSB) said in a July 17 investigation update.

Personnel at the Honeywell Performance Materials and Technologies plant flagged the reboiler shell for replacement in 2020, citing an estimated 1.1 years of operational life. The company conducted ultrasonic thickness testing in 2020 and followed that in 2021 and in October 2021 (in an internal visual inspection of the reboiler.

Management approved the project but did not purchase or install a replacement shell before the Jan. 23, 2023, explosion, CSB reported in its investigation update.

A boiling liquid expanding vapor explosion occurred due to the conditions inside the reboiler at the time of failure. This resulted in the sudden release of hydrogen fluoride, chlorine gas and other substances from the reboiler, distillation column and other ancillary equipment.

The explosion led to the release of more than 870 pounds of hydrogen fluoride and nearly 1,700 pounds of chlorine gas, both highly toxic substances. Local officials closed nearby highways, and workers at the facility sheltered in place. Honeywell estimates the property damage to be approximately $4 million.

CSB said it is continuing to investigate relevant company policies, procedures and standards.