Solvent leak suspected to have triggered Andhra Pharma factory blast, injured out of danger, Rs 1 cr ex gratia announced

The report by the factories department suggest that the mixture of Methyl Tert-Butyl Ether (MTBE) prepared in the reactors was being transferred to a storage tank when the mixture leaked.

Hyderabad: Even as at least 41 injured workers have been undergoing treatment at several hospitals, preliminary findings by the state factories department suggest that a solvent leak triggered the explosion at the Escientia Advanced Sciences factory located in Atchutapuram SEZ in Anakapalli district, which killed at least 17 people on Wednesday.

According to the preliminary investigation report by the factories department accessed by DH the MTBE at a boiling point 55°C and Flash Point -32.78 °C was being transferred from the receiver in the second floor floor via production Lab to the storage tank in the ground floor when the leak happened.

“While leakage is observed and before arresting the leakage the vapour accumulated and formed Vapour cloud. The workers in the PD lab may have tried to come out from the room, the fresh air might have entered and led to Vapour Cloud Explosion. Subsequently extended the fire and smoke through ducts of Air Handling Units to other four modules in the production block,” said the report.

Sources in the Andhra Pradesh government said that the report by the factories department suggested that the mixture of Methyl Tert-Butyl Ether (MTBE) prepared in the reactors was being transferred to a storage tank when the mixture leaked.

The leak occurred while transferring the chemical from the reactor in the production block to the tank through a pipeline. The mixture reacted with the atmosphere, turning into vapour. This vapour then mixed with other gases in the atmosphere, caused a sudden explosion and a massive blast in the factory.

“It will be known today if the reactor also exploded or if it was only the solvent leak that caused atmospheric changes that led to the blast and disaster,” said a senior government official.

Fingers are now being pointed at the alarms for failing to detect solvent leaks. There should be a system in place to alert authorities immediately if a leak occurs during the transfer of chemicals from the reactor to the tank.

Advanced safety systems are currently available to detect changes in the factory atmosphere. An investigation is underway to determine why the spread of vapour-forming gases throughout the factory went undetected.

Vapour Cloud Explosion (VCE)

Experts from the pharmaceutical industry's safety norms classified the incident in Anakapalli chemical factory on Wednesday as a vapour cloud explosion (VCE). A VCE occurs when a flammable vapour cloud is ignited, causing a rapid release of energy.

“In this case, the leak of Methyl Tert-Butyl Ether (MTBE) created a flammable vapour cloud, which then mixed with air and ignited, resulting in a sudden explosion. The characteristics of the incident match the definition of a VCE,” said an industry safety expert.

VCEs are a type of explosion that can occur in industrial settings, particularly in facilities handling flammable liquids or gases. The incident in Achutapuram appears to be a classic example of a VCE.

VCEs can be devastating, causing damage to equipment and structures, as well as injuring or killing people in the surrounding area. They can also lead to secondary fires and explosions.

The explosion was so intense and severe that it tore apart the building's concrete roof and collapsed the walls. Body parts of the victims flew all around, some of which were thrown as high as nearby treetops.

Injured out of danger

Meanwhile, the government said that injured people are out of danger. The officials revealed that the injured people in the Atchutapuram industry accident are safe, and there is no chance of further loss of life.

Of the total 17 dead, 12 bodies have been handed over to family members, and five dead bodies are in the hospital. A private hospital in Visakhapatnam is treating around 41 people.

Rs One Cr Ex Gratia

The government said that injured people are out of danger. According to the officials, the injured people in the Atchutapuram industry accident are safe, and there is no chance of further loss of life. The Andhra Pradesh government has announced an ex-gratia payment of Rs 1 crore to the families of those who lost their lives in Wednesday’s pharmaceutical company blast in Anakapalli. The government has also announced Rs 50 lakhs for the severely injured and Rs 25 lakhs for the moderately injured.

Chief Minister N Chandrababu Naidu visited the Achyutapuram SEZ mishap site and inspected the damage caused by the fire at the Escientia Pharma plant. He also visited the Medicover and KG hospitals in Visakhapatnam to console the injured.

He enquired about the details of the incident and reassured the victims, stating that the government would take care of everything and advising the medical professionals to provide the best possible treatment. He announced a compensation of Rs 1 crore to the families of the deceased, Rs 50 lakh for those with severe injuries, and Rs 25 lakh for those with minor injuries.

“This tragic incident has deeply affected me since yesterday. It serves as an example of what can happen when a company does not make proper decisions. The Escientia Pharma Company was placed in the red category. The incident led to the deaths of 17 people, with some suffering severe burns: 54pc for one person, 24pc for another, 17pc for one, and 10pc for another. The rest had minor injuries. I initially visited those with severe injuries and then spoke to the families of the deceased at KG Hospital. The sight was very painful. One young woman who was four months pregnant also lost her life, which is extremely heartbreaking. After speaking with everyone, I assured them of my support,” Naidu told the media after conducting a review meeting with officials.

He also said that on the one hand, we need industries, and on the other, we must prioritize safety. Following proper SOPs could prevent such problems. In the past five years, Naidu said there have been 119 incidents and 120 deaths in the Vizag region alone.

“For example, in 2020, there were four incidents; in 2021, three; in 2022, four; in 2023, five. Prior to this, in April, there was an incident at LG Polymers. The chemicals involved were explosive, unlike the poisonous chemicals in other incidents. The building's condition was alarming, as powerful blasts caused walls to collapse and threw people onto fences,” he said.

Case booked against Escientia

The Andhra Pradesh government was not satisfied with the response from the promoters of Escientia Advanced Sciences, where the mishap took place.

The state home minister, Vangalapudi Anitha, said that severe action will be taken regarding the incident. Rambilli Police registered an FIR against Escientia Advanced Sciences under sections BNS 106 (1), 125 (b), and 125 (a).

Escientia, based in South Windsor, Connecticut, in the US, is a global contract research, development, and manufacturing organisation (CDMO) serving pharmaceutical and biotech companies in the discovery, development, and launch of small-molecule drugs.

Escientia was founded in 2007 by a Telugu NRI Dr Yadagiri Pendri, 15 years ago in the US. The company's co-founder and President, Kiran Pendri, leads Escientia's efforts to expand its capabilities and capacity.

The company has two R&D centres in Connecticut (US) and Hyderabad, as well as a GMP commercial manufacturing site at Atchutapuram SEZ in Anakapalli district.

The Anakapalli site manufactures intermediate chemicals and APIs (active pharmaceutical ingredients). It came into production in April 2019 with an investment of Rs 200 crore.

The campus is situated on 40 acres in the APIIC Multi-Product SEZ, Atchutapuram Cluster, Anakapalli District.

List of deceased

Neelapu Rami Reddy (49), Associate General Manager/Associate Director, Kotha Venkojipalem, Visakhapatnam

Hansa Prashanth (34), Senior Executive, Ponduru, Srikakulam District

Mahanti Narayana Rao (34), Assistant Manager/Team Leader, Arthamuru, Garividi, Vizianagaram District

Kopparti Ganesh Kumar (33), Senior Executive, Juvvala Doddi, Bikkavolu, East Godavari District

Chalapalli Hari (22), Trainee Engineer, Ramannayyapeta, Kakinada

Paidi Rajasekhar (23), Trainee Process Engineer, Vanjangi, Amudalavalasa Mandal, Srikakulam District

Marisetti Satesh (31), Senior Executive, Pasarlapudi, East Godavari District

Mondina Nagababu (36), Assistant Manager, Samarlakota

Nageswara Ramachandra Rao (47), Assistant Manager/Team Leader, Kurmannapalem, Visakhapatnam

Ellabilli Chinnarao (27), Painter, Achutapuram, Anakapalli District

Javvadi Parthasarathi (27), Fitter, Parvathipuram

Pudi Mohan Durga Prasad, Housekeeping Boy, Achutapuram, Anakapalli District

J. Chiranjeevi (25)

J. Anandarao (35)

M. Suresh, Ashwarao Pet, Khammam