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First accident Cause: run away reaction On Wednesday, April 8, 1998, at 8:18 pm, an explosion and fire occurred during the production of Automate Yellow 96 Dye at the Morton International, Inc (now Rohm 8 Hass) plant (the plant) in Paterson, New Jersey. The explosion and fire were the consequence of a run away reaction, which over pressured a 2000-gallon capacity chemical reactor vessel (or kettle) and released flammable material that ignited. Because of the serious nature of the incident, including injuries to nine employees, the release of potentially hazardous material into the community, and extensive damage to the plant. The Paterson plant manufactures a series of dye products, Yellow 96 Dye was produced by the mixing and reaction of two chemicals, ortho-nitrochloro benzene ( 0-NCB ) and 2-ethylhexylamine ( 2-EHA ). The dye was used to tint petroleum fuel products. The reaction accelerated beyond the heat-removal capacity of the kettle. The resulting high...

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