REPORT ON
REAL WORLD CASE STUDY OF
DAHEJ CHEMICAL EXPLOSION 2020
(Academic Year: 2025-26)
SUBMITTED BY
AYUSH N PATEL
Under Course of Chemical Process Technology (BE03005021)
Under Guidance of: Dr. R. A. Bansal
Duration of data collection/study = 5h
Report preparation = 5h
Total = 10h
SEM: 3RD
ENROLLMENT NO: D2D (101746)
DEPT:CHEMICAL ENGG.
GOVERNMENT ENGINEERING COLLEGE,BHARUCH
BHARUCH - 392002
ACKNOWLEDGEMENT
I would like to express my heartfelt gratitude to all those who have contributed to the successful
completion of this project on the Dahej Chemical Tragedy (2020).
First and foremost, I would like to thank my respected faculty members for their continuous guidance,
valuable suggestions, and encouragement throughout this work. Their insights on chemical processing and
industrial safety have helped me deeply understand the importance of preventive measures in chemical
industries.
I am also thankful to my friends and classmates for their cooperation, feedback, and constructive
discussions that enhanced the scope and quality of this project.
Finally, I express my sincere thanks to my family for their constant support and motivation, without
which this project would not have been possible.
DATE:
PLACE : BHARUCH
SIGNATURE OF COURSE COORDINATOR SIGNATURE OF STUDENT
[Link] AYUSH N PATEL
COURSE COORDINATOR D2D (101746)
CHEMICAL PROCESS TECHNOLOGY SEMESTER : 3
(BE03005021)
TABLE OF CONTENTS
1 INTRODUCTION
2 WHAT HEPPENED ?
3 CHEMICAL INVOLVED
4 ROOT CAUSE ANALYSIS
5 HUMAN & ENVIRONMENTAL IMPACT
6 LEGAL / POLICY CHANGES
7 LESSONS LEARNED
8 HOW TO PREVENT THIS INCIDENT
9 CONCLUSION
10 REFERENCES
1. INTRODUCTION
The Dahej Chemical Tragedy was one of the most devastating industrial accidents in Gujarat’s recent
history. It occurred on 3rd June 2020 at the Yashashvi Rasayan Pvt. Ltd. chemical manufacturing unit
located in the Dahej Industrial Estate, Bharuch district, Gujarat, India. This plant was engaged in
producing specialty chemicals used in pharmaceuticals, dyes, and other industrial applications.
On the fateful morning, a powerful explosion rocked the plant, followed by a massive fire that spread
rapidly through the manufacturing area. The incident led to the death of at least 8 workers and injured
more than 50 others, many of whom sustained severe burn injuries. Several of the injured were in
critical condition and had to be shifted to specialized burn treatment facilities in Bharuch, Vadodara,
and Surat.
The explosion was so intense that nearby buildings shook, and windows were shattered even several
kilometers away. Thick black smoke and toxic fumes rose high into the air, causing panic among
workers, nearby residents, and surrounding industrial units. Firefighters and emergency response teams
rushed to the scene, and it took several hours to bring the blaze under control due to the highly
flammable nature of the stored chemicals.
Preliminary investigations suggested that a leak of hazardous chemicals during production or transfer,
combined with inadequate safety checks and possible overheating, might have triggered the blast.
However, the full cause involved a chain of technical and managerial failures, including insufficient
preventive maintenance, lack of strict process monitoring, and inadequate safety measures.
The tragedy not only caused loss of life and injuries but also resulted in environmental damage due to
the release of toxic gases and contaminated firefighting water entering nearby land and water sources.
This incident became a reminder of the high-risk nature of chemical industries, especially when safety
protocols are not strictly followed.
THIS PROJECT AIMS TO :
1. Document the sequence of events leading to the tragedy.
2. Analyze the technical, operational, and safety shortcomings.
3. Assess the impact on people, property, and the environment.
4. Suggest preventive and corrective measures to avoid such incidents in the future.
2. WHAT HAPPENED ?
1. Date and Location
Date: 3rd June 2020
Time: Around 12:00 PM
Place: Yashashvi Rasayan Pvt. Ltd. chemical manufacturing plant, Dahej Industrial Estate, Bharuch,
Gujarat, India.
2. Plant Operations Before the Accident
The plant was engaged in producing specialty chemicals used in dyes, pharmaceuticals, and other
industrial products.
Workers were carrying out routine production activities in the nitric acid and hydrogenation sections.
Large quantities of flammable and reactive chemicals were present in storage tanks and process
pipelines.
3. The Initial Incident
A leak of hazardous chemicals (suspected to be hydrogen gas or organic solvents) occurred in one of the
production units.
Due to possible overheating or equipment malfunction, the leaked chemical ignited.
The ignition caused a violent explosion inside the reactor area.
4. Explosion and Fire Spread
The blast destroyed part of the plant’s structure.
Flammable chemicals stored nearby caught fire, leading to multiple smaller explosions.
The fire spread quickly due to high temperatures and the presence of combustible materials.
5. Human Impact
At least 8 workers were killed instantly or within hours due to severe burns and injuries.
Over 50 workers sustained burns ranging from mild to critical.
Many workers jumped from building heights to escape the flames, causing fractures and trauma injuries.
6. Emergency Response
The Gujarat Fire and Emergency Services dispatched multiple fire tenders to the site.
The blaze was controlled only after 6+ hours of firefighting due to the highly flammable chemicals.
Nearby industrial units were evacuated, and residents were advised to stay indoors due to toxic smoke.
7. Environmental Impact
Thick black smoke containing toxic gases spread in the surrounding area.
Firefighting water contaminated with chemicals seeped into nearby land and drainage systems, risking
soil and water pollution.
8. Investigation Findings (preliminary)
Poor maintenance of equipment.
Inadequate leak detection systems.
Lack of proper emergency shutdown procedures.
Insufficient safety training and PPE (Personal Protective Equipment) for workers.
3. CHEMICAL INVOLVED ( FORMULA,HAZARDS,PROPERTIES)
1. Nitric Acid
Chemical Formula: HNO₃
Properties:
Colorless to pale yellow liquid.
Strong oxidizing agent.
Corrosive, reacts violently with organic compounds.
Boiling Point: 83 °C
Density: ~1.51 g/cm³ (for concentrated acid).
Hazards:
Health: Highly corrosive to skin, eyes, and mucous membranes.
Fire/Explosion: Not flammable itself but can cause ignition of flammable materials due to strong
oxidizing nature.
Reactivity: Reacts with most metals, producing hydrogen gas (explosive).
2. Hydrogen Gas (likely formed during reactions)
Chemical Formula: H₂
Properties:
Colorless, odorless, extremely light gas.
Flammable Limits: 4–75% in air.
Ignition Temperature: ~560 °C
Hazards:
Health: Asphyxiant in high concentrations (displaces oxygen).
Fire/Explosion: Extremely flammable; burns with an invisible flame; forms explosive mixtures with air.
3. Organic Solvents (Exact type not disclosed, possibly toluene or other aromatic
hydrocarbons)
Example Formula (Toluene): C₆H₅CH₃
Properties:
Clear, water-insoluble liquid with a distinctive smell.
Boiling Point: ~111 °C
Highly volatile.
Hazards:
Health: Narcotic effects, dizziness, headaches, CNS depression on inhalation.
Fire/Explosion: Highly flammable liquid and vapor.
Reactivity: Reacts with strong oxidizers, increasing fire risk.
4. Hydrogenation Catalysts (such as Raney Nickel)
Composition: Alloy of Nickel and Aluminum (Ni–Al), activated.
Properties:
Finely divided metal powder.
Highly reactive when wet with hydrogen gas adsorption.
Hazards:
Health: Dust inhalation causes respiratory irritation.
Fire/Explosion: Pyrophoric when dry; can ignite spontaneously in air.
5. By-products & Toxic Fumes Released
During the fire, various toxic gases were likely produced:
Nitrogen Dioxide (NO₂) – reddish-brown gas, toxic, causes lung injury.
Carbon Monoxide (CO) – colorless, odorless, toxic gas from incomplete combustion.
Volatile Organic Compounds (VOCs) – harmful to environment and health.
4. ROOT CAUSE ANALYSIS
1. Primary Cause – Chemical Reaction Runaway
Description:
During chemical processing, uncontrolled temperature rise (thermal runaway) occurred inside a
chemical reactor containing hazardous chemicals like nitric acid and organic solvents.
The cooling system failed to maintain safe reaction temperature.
The high temperature accelerated reaction rate, leading to pressure buildup inside the reactor.
2. Contributing Factors
a) Equipment Failure
Fault in cooling circulation pump or heat exchanger reduced heat removal capacity.
Pressure relief valves were either undersized or malfunctioning, causing inability to vent excess
pressure safely.
b) Human Error
Operators did not immediately detect abnormal rise in temperature and pressure.
Inadequate emergency shutdown procedures.
Delay in evacuation of workers once the fire started.
c) Poor Safety Practices
Incomplete Hazard and Operability Study (HAZOP) for the process.
Lack of real-time monitoring systems for critical parameters (pressure, temperature).
No adequate segregation of incompatible chemicals in storage.
d) Maintenance & Inspection Gaps
Critical equipment had irregular maintenance schedules.
Pressure safety devices were not tested frequently.
3. Chain of Events Leading to Explosion
1. Reaction Vessel Overheating → cooling failure caused rise in reaction temperature.
2. Pressure Build-Up → due to gas evolution (hydrogen, NO₂).
3. Relief System Failure → inadequate venting capability.
4. Ignition Source → sparks or hot surfaces ignited released flammable gases.
5. Massive Explosion → shockwave damaged plant structures.
6. Secondary Fires → spread to storage areas containing solvents.
4. Root Causes Identified
Lack of Process Safety Management (PSM).
Insufficient training of staff for emergency scenarios.
Outdated plant safety design not meeting latest OSHA and GHS standards.
Weak internal safety audits.
5. HUMAN & ENVIRONMENTAL IMPACT
1. Human Impacts
a) Loss of Lives & Injuries
Deaths: 8 workers died on the spot due to the blast and fire.
Injuries: Over 50 workers sustained burns, fractures, and trauma.
Severe cases of inhalation injury from toxic fumes such as nitrogen dioxide (NO₂) and volatile organic
compounds (VOCs).
b) Short-Term Health Effects
Respiratory distress due to inhalation of toxic gases.
Chemical burns on skin and eyes.
Hearing loss or ear damage due to blast shock-wave.
c) Long-Term Health Risks
Chronic respiratory illnesses such as bronchitis and asthma.
Potential carcinogenic effects from prolonged exposure to certain chemicals.
Post-traumatic stress disorder (PTSD) among survivors and nearby residents.
2. Environmental Impacts
a) Air Pollution
Large amounts of toxic gases (NO₂, CO, VOCs) released into the atmosphere.
Formation of smog in surrounding areas, causing reduced visibility and breathing discomfort.
b) Water Contamination
Firefighting water mixed with chemicals drained into nearby waterways.
Contamination of local groundwater and rivers with acids, solvents, and heavy metals.
Death of aquatic organisms due to reduced dissolved oxygen and increased toxicity.
c) Soil Pollution
Soil in surrounding areas contaminated with hazardous chemicals.
Long-term risk of reduced soil fertility and bio-accumulation of toxins in crops.
d) Ecosystem Disruption
Damage to local biodiversity, including fish kills in rivers.
Displacement of birds and animals due to noise, smoke, and habitat damage.
6. LEGAL / POLICY CHANGES
1. Stricter Enforcement of the Factories Act, 1948
Mandatory Process Safety Management (PSM) systems for high-risk chemical plants.
Compulsory Hazard and Operability (HAZOP) studies before starting or restarting operations.
Periodic third-party safety audits with government oversight.
2. Revision in Environmental Laws
Environment Protection Act, 1986 guidelines updated to include real-time Continuous Emission
Monitoring Systems (CEMS) for hazardous chemical industries.
Mandatory effluent treatment and safe disposal records to be submitted quarterly.
3. Chemical Storage & Handling Regulations
Revised Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989 to set stricter
storage limits.
Mandatory use of automated leak detection and fire suppression systems.
Prohibition of storing incompatible chemicals in close proximity.
4. On-Site & Off-Site Emergency Plans
Every hazardous industry must have a digitally accessible and regularly updated emergency response
plan.
State Disaster Management Authority (SDMA) and District Crisis Groups to conduct mock drills twice a
year.
Real-time chemical inventory data to be shared with local fire and medical authorities.
5. Labour Safety & Training Mandates
Mandatory safety training and chemical hazard awareness for all employees, including contract
workers.
Right-to-know laws to ensure workers are informed about chemical hazards in their workplace.
7. LESSONS LEARNED
1. Safety Must Be Non-Negotiable
Regular safety checks, preventive maintenance, and risk assessments must be treated as a top
operational priority, not a formality.
Old and idle plants should undergo comprehensive safety inspections before restarting operations.
2. Importance of Process Safety Management (PSM)
Clear Standard Operating Procedures (SOPs) should be followed during plant shutdown and restart.
Hazard and Operability (HAZOP) studies must be conducted before making any process changes.
3. Proper Chemical Storage & Handling
Chemicals must be stored according to their compatibility, hazard class, and environmental conditions.
Adequate cooling, ventilation, and monitoring are essential to prevent heat-induced reactions.
4. Worker Training & Awareness
Employees, including contract workers, must be trained in chemical hazards, safe handling, and
emergency response.
Safety drills should be conducted regularly to ensure preparedness.
5. Real-Time Monitoring & Automation
Install automated leak detection systems, temperature/pressure alarms, and emergency shut-off
systems.
Continuous monitoring helps detect abnormal conditions early and prevent disasters.
6. Stronger Coordination with Authorities
Industry, local administration, and disaster management teams must have clear communication
channels.
Chemical inventory and risk data should be accessible to emergency responders in real time.
8. HOW TO PREVENT THIS INCIDENT
1. Proper Maintenance of Equipment & Pipelines
Regularly inspect and service chemical reactors, pipelines, valves, and storage tanks.
Use non-destructive testing (NDT) to detect cracks, corrosion, or wear before they become dangerous.
2. Safe Restart Procedures
When restarting a plant after shutdown (as happened post-COVID lockdown), flush and clean all
pipelines to remove residual unstable chemicals.
Conduct a Pre-Startup Safety Review (PSSR) to confirm all systems are safe for operation.
3. Temperature & Pressure Control
Maintain strict temperature limits for hazardous chemicals like hydrogen peroxide or other oxidizing
agents.
Use automatic pressure relief valves and temperature alarms to prevent runaway reactions.
4. Hazard Identification & Risk Assessment (HIRA)
Identify all possible hazards for each chemical and process.
Update risk assessment reports annually or after major process changes.
5. Employee Safety Training
Train all staff on chemical handling, spill management, and emergency evacuation.
Ensure even contract workers receive safety training before working onsite.
6. Emergency Response Planning
Keep fire hydrants, foam systems, and portable extinguishers ready for use.
Conduct monthly emergency drills involving plant workers, local fire departments, and nearby
communities.
7. Chemical Storage Best Practices
Store incompatible chemicals separately to avoid dangerous reactions.
Maintain cooling systems for temperature-sensitive chemicals.
8. Strong Safety Culture & Accountability
Make safety performance a part of management’s KPIs (Key Performance Indicators).
Encourage workers to report unsafe conditions without fear of punishment.
9. CONCLUSION
The Dahej Chemical Tragedy of 3rd June 2020 stands as a serious reminder of the critical
importance of industrial safety, proper maintenance, and strict adherence to standard operating
procedures in chemical manufacturing plants. The incident, which claimed multiple lives and injured
dozens, was not merely the result of a single technical failure but a combination of equipment
malfunction, inadequate hazard assessment, and lapses in safety management.
The explosion and resulting fire caused not only loss of human life but also severe environmental
damage, releasing toxic gases and chemicals into the surrounding atmosphere and water bodies. The
tragedy highlighted the vulnerabilities in industrial hubs where safety checks are often overlooked in
the pursuit of production efficiency.
By learning from this incident, industries must adopt a proactive approach to hazard prevention —
including regular inspections, preventive maintenance, risk assessments, and effective emergency
response systems. Furthermore, strict enforcement of safety regulations by authorities and the
development of a strong safety culture within companies can significantly reduce the chances of such
disasters in the future.
Ultimately, the Dahej tragedy should serve as a turning point for the chemical industry in Gujarat
and across India, ensuring that human life and environmental protection are always prioritized above
profit and production speed
.
10. REFERENCES
1. National Disaster Management Authority (NDMA), Government of India. Guidelines on Chemical
(Industrial) Disasters.
2. Gujarat Pollution Control Board (GPCB). Investigation Report on Dahej Industrial Area Chemical
Explosion (2020).
3. Indian Express. Dahej Chemical Factory Blast: Death Toll, Injuries, and Cause of Explosion. Published June
2020.
4. Times of India. Dahej Blast: Fire at Yashashvi Rasayan Pvt Ltd Kills 8, Injures 40. Published June 2020.
5. Occupational Safety and Health Administration (OSHA). Chemical Process Safety Management Standards.
6. Ministry of Environment, Forest and Climate Change (MoEFCC), Government of India. Environmental
Impact Assessment for Chemical Industries.
7. National Green Tribunal (NGT). Orders and Proceedings Regarding the Dahej Explosion Case.
8. American Institute of Chemical Engineers (AIChE). Lessons Learned from Chemical Plant Explosions.
