Chemical Release Accident Caused by the Abnormal Reaction of Potassium Permanganate Mixtures during Optical Film Manufacturing: A Brief Case Review

Abstract

Small- and large-scale accidents often occur in workplaces handling hazardous chemical substances. These accidents are usually caused by leaks, explosions, fires and complex chemicals; a large proportion of these chemical accidents are caused by leaks. A chemical release accident that injured four people occurred during an optical film-manufacturing process. This report analyzes the causes of this accident and provides effective measures for accident prevention. This accident was caused by an abnormal reaction during the input of raw materials prior to their heating. Tertiary butyl alcohol (t-BuOH), distilled water (DW), and potassium permanganate (KMnO4) were mainly used in this process. We found that this mixture reacted with unknown impurities. After KMnO4 was added to the mixture of t-BuOH and DW, a large amount of heat was suddenly released from the reactor for one minute. In particular, a small amount of methanol (4%), which could have entered the mixture during the cleaning process, and seal oil containing glycerin (13%) were suspected to be the key materials influencing the rapid reaction. Given the significant findings about this accident, the precautionary technical/administrative measures we provide herein may help prevent such accidents in future.