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Phillips 66 (2538), Lake Charles

LDEQ Accident Report

Accident #112924
State Police #09-00885
Accident Date2009-02-21
Report Date 2009-02-27
Follow-up Date 2009-03-00
Follow-up: Yes

Pollutants Released

Pollutant Duration Point Source Greenhouse Gas Criteria Pollutant Ozone forming chemical Amount of Release
Sulfur Dioxide16hArea A, B, and C heater stacksNOYESNO716.0 pounds

Accident Classified As:

Cause of Problem: Process Upset

The skimming of hydrocarbons at the #3 Flash Drum led to a foaming upset of the regenerator and inefficient H2S removal from the amine utilized in the high pressure fuel gas (HPFG). This caused a #3 Amine Regeneration Unit (ARU) system upset that resulted in combustion of refinery fuel gas with high H2S in the HPFG system. Ultimately, this caused SO2 to be released from fired heater stacks in Areas A, B, and C.

Discharge Preventable - No

Hydrocarbon skimming has to be done to prevent regenerator foam ups.

Notes/Remedial Actions

NOTE: Follow-up occurred on 3/31/09. Exceeds RQ. Immediate action taken was to add anti-foam to get the system back to normal and cleaning up the amine. Firing rates of heaters reduced to decrease SO2 released. Planned remedial action include increase frequency of skimming the #3 Amine Flash Drum to prevent sending large amounts of hydrocarbon to the regenerator all at once.