Authors: Karolína Hrabovská, Karel Lehmert Affiliation: Dept. of Criminology & Forensic Studies, University of Finance and Administration, Prague, Czech Republic Keywords: styrene, LG Polymers, autopolymerization, HAZMAT, process safety, Vizag
Introduction
On 7 May 2020, a serious industrial accident occurred at the LG Polymers plant in Visakhapatnam, India, involving the release of toxic styrene vapours. The event took place during a nationwide COVID-19 lockdown, which affected normal plant operation. Due to reduced activity and limited staff, the risks related to long-term storage of hazardous chemicals were underestimated. The released vapours formed a toxic cloud that spread over nearby residential areas within several kilometres.
Methodology
This work is based on a case study approach using the official investigation report of the National Green Tribunal and data from styrene safety data sheets. The analysis includes reconstruction of the autopolymerization process in tank RR-M62 and evaluation of the response carried out by NDRF units. The study focuses on mitigation measures such as water curtains and the use of chemical inhibitors. It also examines the link between health effects in the population and the toxicological properties of styrene, especially in the context of safety failures during the pandemic period.
Results
The main cause of the accident was an uncontrolled exothermic reaction known as autopolymerization. This occurred in tank RR-M62 due to failure of the cooling system and prolonged storage of styrene without circulation. As a result, the temperature increased rapidly and toxic vapours were released through safety valves into the surrounding area.
The incident resulted in 13 fatalities and more than 500 hospitalizations. Reported symptoms included acute respiratory distress, chemical conjunctivitis, and central nervous system depression. Approximately 20,000 people from nearby villages had to be evacuated. Specialized NDRF units used water curtains to reduce the spread of the toxic cloud. Stabilization was achieved only after air transport and application of approximately 500 kg of the inhibitor PTBC directly into the affected tank.
Discussion
The Vizag incident shows a serious failure of process safety management and highlights risks related to operating chemical facilities during extraordinary situations such as a pandemic. A key issue was the lack of effective warning systems that could inform the local population on time. Insufficient temperature monitoring led to the formation of thermal hotspots, which were not detected due to reduced staffing. This case confirms that CBRNE preparedness must include not only technical safety measures, but also effective communication and early warning systems for people living in risky areas.
References
- National Green Tribunal (2020). Investigation report on the gas leak at the LG Polymers plant in Visakhapatnam. Delhi, India.
- Reddy, M. S. et al. (2021). Analysis of the styrene leak in Vizag: Lessons learned for industrial safety. Journal of Chemical Health and Safety, 28(5), 412–420. https://doi.org/10.1016/j.jchas.2021.05.003
- NDMA (National Disaster Management Authority) (n.d.). Methodological guidelines for the management of chemical and HAZMAT disasters. Government Guidelines, India.
- MSDS (n.d.). Toxicological profile and safety parameters of styrene monomer (CAS 100-42-5).
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