CSB Launches Investigation Into Fatal Hydrogen Sulfide Release at West Virginia Catalyst Plant
Photo by Robin Vintevogel on Unsplash
The U.S. Chemical Safety Board is investigating a fatal incident at Catalyst Refiners in Nitro, WV, involving a toxic chemical reaction during equipment decommissioning.
Key Facts
- The incident occurred on April 22 during the cleaning and decommissioning of equipment at the Nitro, West Virginia facility.
- A reaction involving nitric acid and an unidentified substance generated toxic hydrogen sulfide gas.
- Two workers were killed and more than 30 others required medical care following the release.
- The facility is owned by Ames Goldsmith Corporation and refines silver and ethylene oxide catalysts.
- A shelter-in-place order was issued for the surrounding community during the event.
What Happened
On April 23, the U.S. Chemical Safety and Hazard Investigation Board (CSB) announced the commencement of a formal investigation into a fatal chemical release at the Catalyst Refiners, Inc. facility in Nitro, West Virginia. The incident, which occurred the previous day on April 22, resulted in the deaths of two workers and left more than 30 others seeking medical attention. One individual was reportedly in critical condition following the event.
Initial reports indicate that the release took place inside a building where numerous employees were present. The board found that the incident was triggered by a chemical reaction during the cleaning and decommissioning of facility equipment. During this process, nitric acid was mixed with another substance, which led to the generation and subsequent release of toxic hydrogen sulfide gas.
Why It Matters
This incident underscores the high-risk nature of maintenance and decommissioning phases in chemical processing. While routine operations often have established safety parameters, the mixing of cleaning agents like nitric acid with residual process chemicals can create lethal unintended reactions. The report said the generation of hydrogen sulfide gas in this instance was severe enough to necessitate a shelter-in-place order for the surrounding community.
For EHS leads and industrial operators, the CSB investigation will likely focus on the protocols used during equipment turnover. Chairperson Steve Owens stated that the agency intends to determine the cause of the incident to identify preventive measures for the industry. Understanding how these substances were allowed to mix is critical for facilities handling similar hazardous materials.
Key Details
Catalyst Refiners, Inc. is a subsidiary of the Ames Goldsmith Corporation. The facility's primary operations involve the following specialized processes:
- Silver catalyst refining and processing
- Ethylene oxide catalyst refining
- Equipment decommissioning and specialized cleaning
- Handling of concentrated nitric acid
The CSB is an independent, nonregulatory federal agency. Unlike OSHA or the EPA, the CSB does not issue fines or citations. Instead, it is charged with identifying the root causes of catastrophic releases and formulating safety recommendations to prevent future occurrences. The board members are appointed by the president and confirmed by the Senate.
What To Watch Next
The CSB investigation team will remain on-site to gather evidence and interview witnesses. Stakeholders should expect a detailed report in the coming months that outlines the specific chemistry and procedural failures that led to the hydrogen sulfide generation. These findings often serve as the basis for new safety recommendations issued to industry organizations and regulatory bodies like OSHA.
As the investigation progresses, the identity of the "other substance" that reacted with the nitric acid will be a point of significant interest for lab managers and process engineers. Identifying this reactant will help other catalyst refining facilities update their hazard communication and standard operating procedures for equipment maintenance.
Alliance's Take
This incident highlights the extreme volatility associated with equipment decommissioning and the critical need for rigorous chemical compatibility testing before cleaning procedures begin. Industrial operators should re-evaluate their nitric acid handling protocols, specifically ensuring that all residual materials are identified and cleared before introducing strong oxidizers into the system.
From a procurement and safety standpoint, the potential for hydrogen sulfide generation remains a top-tier hazard in catalyst refining. We advise our customers to review their sensor placement and emergency response plans for H2S, particularly in enclosed buildings where maintenance and decommissioning activities are scheduled to occur.
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Frequently Asked Questions
What chemicals were involved in the West Virginia incident?
The incident involved a reaction between nitric acid and an unidentified second substance, which resulted in the release of toxic hydrogen sulfide gas.
What was the facility doing when the release occurred?
The release happened during the cleaning and decommissioning of equipment at the Catalyst Refiners facility, which specializes in silver and ethylene oxide catalyst refining.
Will the CSB issue fines to the company?
No, the CSB is a nonregulatory agency that does not issue citations or fines. Its role is to conduct root cause investigations and make safety recommendations to companies and regulatory agencies like OSHA.
