Accident at OCI Malaysia’s polysilicon plant injures ten workers

A fire after the explosion of a bottom reactor pipe at OCI Malaysia’s polysilicon plant in the Samalaju Industrial Park in Bintulu, Sarawak state has injured ten workers through smoke inhalation; four have also suffered severe burns. The major accident occurred on August 14.

While most Malaysian media only mentioned a fire at an anonymous factory in the Samalaju Industrial Park in Bintulu, the TV news channel Astro Awani identified OCI’s polysilicon plant as the location of an accident on August 14. At 6:24pm local time, the Samalaju fire station received a distress call. According to the Borneo Post, the fire was already extinguished by the factory’s Emergency Response Team before the local fire brigade arrived on the scene.

Ten injured workers were rushed into the hospital in Bintulu. Four are in the intensive care unit, three in the burn treatment unit, and three are awaiting treatment in the surgical ward.

A huge white vapor plume and a massive brown-gray smoke cloud emerged from the factory. Rumor has it that the fire arose from the leak at a pipe that feeds hydrogen (H₂) and silicon tetrachloride (SiCl₄) into the bottom of a fluidized bed reactor for hydrochlorination of silicon powder to make trichlorosilane (SiHCl₃).

According to Alan Crawford, a U.S.-based methylchlorosilanes and trichlorosilane process consultant, the white plume is a mix of hydrogen chloride (HCl), which comes from the reaction of SiCl₄ with moisture in the air and probably extinguishing water, and of steam from the spontaneous combustion of hydrogen to form water vapor. The brown-gray cloud could have originated from burning trichlorosilane and/or silicon dust exiting from the fluidized bed reactor.

Calls for thorough investigation and consequences in risk management

Bintulu District Police Chief Nixon Joshua Ali said a preliminary investigation has found that the accident was caused by a leak in the main pipe, which exploded “due to too high pressure.”

The Sarawak section of the reformist People’s Justice Party demanded that a “thorough and transparent investigation” of the explosion should be carried out “immediately,” including aspects like industrial licensing, prevention of environmental pollution, and impact on the health of nearby residents.

According to Datuk Seri Tiong King Sing, Federal Minister of Tourism, Arts, and Culture, “a similar incident occurred earlier this year, which clearly shows that the factory’s disaster prevention measures are inadequate.” Tiong added: “I hereby issue a warning: The factory must operate conscientiously, review and enhance its risk management mechanisms, and ensure that such incidents do not happen again.”

Neither OCI Malaysia nor its parent OCI Holdings have made a statement so far.

Update: Two injured workers have passed away

Two of the ten injured workers died a few weeks after the accident. Mohd Fadillah Saliman, 33, and Martin Ulok, 29, succumbed to their injuries on August 29 and September 8, respectively, the Borneo Post reported.

In the case of Saliman, the newspaper referred to a post of OCI Malaysia (OCIM) on its Facebook page. The post seems to have disappeared from the page again. “Our thoughts and prayers are with the victim’s family, friends, and loved ones during this difficult time,” OCIM said according to the Borne Post. “We extend our deepest sympathy and stand with them in their grief. As a company, we are committed to supporting the family in any means we can.”

String of incidents in the global polysilicon industry

The explosion in Bintulu is the latest event in a series of incidents in the global polysilicon industry, both in and outside China:

• June 17, 2022: The leakage of a superheater caused a major fire at Xinjiang-based polysilicon manufacturer East Hope.
• November 13, 2020: One of five contract workers died after a mixture of steam and hydrochloric acid escaped during a maintenance operation at Wacker’s U.S. polysilicon plant.
• July 19/20, 2020: A series of four flash explosions, followed by a fifth on the next day, ripped through the distillation unit of Xinjiang GCL (now Xinjiang Goens); burning heat transfer oil resulted in a huge black smoke cloud.
• September 7, 2017: A faulty piston caused the explosion of a hydrogen compressor at Wacker’s U.S. polysilicon plant, leading to a eight-month shutdown.

Sources

https://www.theborneopost.com/2024/08/14/plant-fire-at-samalaju-industrial-park-leaves-10-injured/

https://www.theborneopost.com/2024/08/15/rep-demands-company-clear-the-air-as-it-remains-silent-on-bintulu-factory-fire/

https://www.theborneopost.com/2024/08/15/pkr-sarawak-wants-immediate-probe-on-bintulu-factory-fire/

https://www.astroawani.com/videos/video-terkini-x7sio1/reaktor-bawah-milik-ocim-sdn-bhd-terbakar-x941hww

https://www.tiktok.com/@jamesukaijim/video/7402947616637488385

https://www.kosmo.com.my/2024/08/15/video-10-cedera-akibat-letupan-tangki-bottom-reactor/

https://dayakdaily.com/bintulu-mp-launches-post-disaster-response-urges-safety-review-after-samalaju-industrial-park-reactor-explosion/

https://www.theborneopost.com/2024/08/30/samalaju-plant-fire-company-expresses-sorrow-over-workers-passing/

https://www.theborneopost.com/2024/09/09/aug-14-samalaju-plant-explosion-another-victim-succumbs-to-injuries/