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On 2-3 December 1984, the world's worst industrial disaster took place in Bhopal, India. The tragedy began with routine maintenance activities in the factory owned

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On 2-3 December 1984, the world's worst industrial disaster took place in Bhopal, India. The tragedy began with routine maintenance activities in the factory owned by Union Carbide India Limited (UCIL). Washing of pipes was performed to keep a filter system clean by flushing contaminants out with water. However, water reached a tank of a highly reactive pesticide intermediate, 42 tonnes of methyl isocyanate (MIC). The pressure gauges connected to the tank were ignored as operators presumed the gauge to be faulty. Also, there was no reliable way of monitoring the tank temperature. The pressure of the tank was supposed to be maintained at a certain level with inert gas to prevent backflow into the tank. However, there was an undetected leaky valve connecting the tank to the plant's main pipe system. If gas could get out, then water could get in. A chemical reaction between MIC and water began and the heat was generated. The reaction mixture inside the tank progressively warmed as conditions moved closer to a thermal runaway reaction. The tank should have been kept cool with a refrigeration system, which had been switched off months earlier. Soon, the thermal runaway reaction took place. Hot MIC vapour burst through the tank's automatic pressure relief system and started to escape through the dysfunctional vent gas scrubber, which was meant to neutralise toxic gas exhaust from the plant. When the operator finally noticed the actual condition inside the tank, it was already too late to stop the catastrophic loss of process containment. At this point, nothing could have been done to stop the release. During the time of the accident occurring, the villagers were sound asleep in midnight. The deadly gas spread and killed at least 4,000 people while causing significant morbidity and premature death for thousands more. Even after nearly 40 years, the aftermath of the tragedy continues to haunt villagers in the area, physically and psychologically. Based on the information provided, please attempt the questions below. (1) Please apply the knowledge from process safety to understand the toxicity of the material MIC. (2) Please draw a flow chart or block diagram to show the series of events leading to the tragedy. (3) Please use the Bow-tie method to summarise the causes and consequences of the toxic gas release. If you were one of the process engineers, please list both prevention and mitigation barriers according to the bowtie diagram created

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