(57f) N.D.K. Crystal Inc. Explosion with Offsite Fatality
AIChE Spring Meeting and Global Congress on Process Safety
2024
2024 Spring Meeting and 20th Global Congress on Process Safety
Process Development Division
Poster Session: Process Development Division
Monday, March 25, 2024 - 5:00pm to 7:00pm
On December 7, 2009, Vessel No. 2 at NDK Crystal Inc. facility in Belvidere, Illinois erupted, causing a white cloud of steam to be released into the air. The force of the eruption broke the base of the steel vessel and led to shrapnel flying offsite. One fragment of steel flew 435 ft. away from the manufacturing area and hit the wall of Grupo Antolin, an automotive supply company close by. One Grupo Antolin employee was injured by the blow. Another fragment of steel flew 650 ft. away and hit a truck driver who had stopped at the Oasis gas station near I-90 highway. This driver later passed away. NDK Crystal, Grupo Antolin, and cars in neighboring parking lots sustained varying degrees of damage. NDK Crystal was later fined for disregarding various national standards. U.S. Chemical Safety Board (CSB) investigators were sent on the scene to discover what caused the incident. After conducting non-destructive evaluations and destructive testing methods on fragments of the autoclave, CSB made many recommendations. CSB encouraged NDK to be prohibited from using the autoclaves until Illinois deemed them safe for use. CSB also recommended NDK find inherently safer ways to produce crystals, like at lower temperatures and pressures. CSB advised The American Society of Mechanical Engineers (ASME) to update their standards on vessel thickness, as NDK had vessels that were susceptible to corrosion due to being overly thick. Along with this, several other recommendations were necessary. This research evaluates the recommendations made by the CSB and assesses the sequence of events that caused this incident.