GROUP 7 - CHE 4202
SEVESO
DISASTER
JULY 10, 1976, IN SEVESO, ITALY
Presented By:
AGMANA, Andrey; RAMIREZ,
Charisse; and FAJILAN, Angela
The Seveso Incident was a 1976 industrial accident in Seveso, Italy,
where a chemical plant released a toxic cloud of dioxin (TCDD),
leading to widespread environmental contamination and health
issues, including chloracne and long-term cancer risks.
CHE 429: Process Safety Engineering
SEVESO DISASTER
INCIDENT SCENARIO
The Seveso disaster occurred on (TCDD) into the
atmosphere. A reactor at the ICMESA plant,
producing 2,4,5-trichlorophenol, overheated,
causing a safety valve to rupture and release the
hazardous substance particularly, 2,3,7,8-
tetrachlorodibenzo-p-dioxin (TCDD). The
contamination affected over
37,000
RESIDENTS
,causing skin lesions like chloracne, animal
deaths, and long-term health concerns, including
cancer risks.
Industrie Chimiche
Meda Società
Azionaria (ICMESA)
FACILITY OVERVIEW
The ICMESA (Industrie Chimiche Meda Società
Azionaria) facility was a chemical manufacturing plant
operated by the Swiss-based Givaudan, a subsidiary
of the Roche Group. The plant specialized in producing
chemical intermediates, including 2,4,5-
trichlorophenol, which is used in the manufacture of
herbicides, disinfectants, and other industrial chemicals.
The facility housed multiple reactors and equipment
2,4,5-Trichlorophenol
(TCP) is an for handling hazardous substances, reflecting the
organochloride with the industrial practices of the time with limited safety
molecular formula
protocols compared to modern standards.
C6H3Cl3O.
TCP Synthesis and Dioxin Formation
ICMESA Chemical Process Overview
1 2 3
Formation of 2,4,5- Acidification to Form
Reactor Setup and
Sodium 2,4,5-Trichlorophenol
Loading
Trichlorophenate (TCP)
The process starts by preparing a At 150°C, TCB reacts with NaOH to At 170°C, Hydrochloric acid (HCl) is
10,000-liter batch reactor equipped produce 2,4,5-sodium added to the mixture, converting
with steam heating, a stirrer, and a trichlorophenate and sodium chloride 2,4,5-sodium trichlorophenate into
safety bursting disc set at 3.8 bar. (NaCl) as a by-product. Xylene 2,4,5-trichlorophenol (TCP) while
facilitates the removal of water releasing NaCl.
through azeotropic distillation
X Dioxin (TCDD) Formation
4
Quenching and
Product Isolation
To stop further reactions, the mixture At elevated temperatures, particularly above 180°C, a side reaction can
is rapidly quenched by adding a large occur, leading to the formation of 2,3,7,8-tetrachlorodioxin (TCDD), a highly
excess of cold water. The solid TCP is toxic dioxin compound. This results from the condensation of two TCP
separated from the liquid phase using molecules under excessive heat: C6HCl3OH→C12H4Cl4O2(TCDD)+H2O
filtration.
SEVESO INCIDENT
July 10, 1976
Reactor shutdown with incomplete solvent
removal
SEVESO INCIDENT
July 10, 1976
Reactor shutdown with incomplete solvent
removal
Unchecked exothermic reaction and
temperature rise
SEVESO INCIDENT
July 10, 1976
Reactor shutdown with incomplete solvent
removal
Unchecked exothermic reaction and
temperature rise
Pressure buildup and bursting disc rupture
SEVESO INCIDENT
July 10, 1976
Reactor shutdown with incomplete solvent
removal
Unchecked exothermic reaction and
temperature rise
Pressure buildup and bursting disc rupture
Toxic cloud spreads over surrounding areas
What led up to the incident and how
did it occur?
Design Deficiencies in Failure to Follow Safety
Equipment Procedures
The equipment lacked critical safety Essential safety protocols were not followed,
features, such as proper temperature leading to unstable conditions during
monitoring, automatic cooling, and shutdown.
containment systems. Incomplete removal of chemicals and lack of
Poor design led to uneven heating, cooling allowed heat and pressure to build
creating unstable conditions that up unchecked.
contributed to the uncontrolled reaction.
What led up to the incident and how
did it occur?
Lack of Risk Awareness Ineffective Communication
and Training and Delayed Response
Workers were not adequately trained to The severity of the situation was not
recognize and respond to potential immediately recognized, leading to delays
hazards. in reporting and response.
Safety measures were not properly Authorities were informed too late, and
enforced, and early warning signs were public warnings were significantly delayed.
overlooked.
Main factors contributed
to the event
Design Operator Violation of Safety
Defficiencies Negligence Procedures
Lack of Safety Ineffective
Awareness Communication
CONSEQUENCES OF
SEVESO INCIDENT
Health Consequences
Environmental Consequences
Financial Consequences
Legal Consequences
HEALTH
CONSEQUENCES
The release of 2,3,7,8-
tetrachlorodibenzo-p-dioxin (TCDD)
caused immediate and long-term
impact on Seveso residents..
Immediate Impact. Residents exposed experienced nausea,
headaches, eye irritation, and skin lesions, while children
developed chloracne.
Long-term Impact. TCDD exposure caused reduced fertility,
increased mortality in chronic diseases and generational illness.
ENVIRONMENTAL
CONSEQUENCES
TCDD is also a corrosive chemical
that can accumulate within the soil
affecting vegetation.
Soil Quality Impact. The Seveso explosion led to the
contamination of 2,000 hectares of soil.
Vegetation Impact. Contamination levels as high as 15.8
ppm of TCDD was found near the chemical plant
Animal Impact. Consumption of contaminated plants
caused the death of 81,131 animals.
Air Quality Impact. Between 0.2 to 0.4 kg of TCDD was
released into the atmosphere.
FINANCIAL
CONSEQUENCES
Roche shut down the plant and
allocated $168 million to cover the
damages. .
The 2 companies, 37 cottage industries, 61 farms, and
4,000 kitchen gardens were also affected.
The court also mandated $19,000 to the Brianza
district council, the hardest-hit community for the
psychological impact.
LEGAL
CONSEQUENCES
By 2001, 21 lawsuits were filed
seeking compensation for
psychological trauma.
Von Zwehl and Sambeth received 5-year sentences,
while Moeri and Waldvogel were sentenced to 4
years.
3 years were deducted for the sentence due to
government amnesty and overpopulation in prison.
LEARNINGS FROM INCIDENT
Stricter Emergency Effective Long-term Responsible
inspection preparedness communication research management
and
management
GROUP 7 - CHE 4202
SEVESO
DISASTER
JULY 10, 1976, IN SEVESO, ITALY
Presented By:
AGMANA, Andrey; RAMIREZ,
Charisse; and FAJILAN, Angela
The Seveso Incident was a 1976 industrial accident in Seveso, Italy,
where a chemical plant released a toxic cloud of dioxin (TCDD),
leading to widespread environmental contamination and health
issues, including chloracne and long-term cancer risks.
CHE 429: Process Safety Engineering
