Philadelphia is a hub of industrial activity, home to numerous power plants, pharmaceutical companies, and manufacturing facilities. These operations are crucial, providing the city and region with essential resources and goods, creating jobs, and boosting the economy. However, some industrial sites pose significant risks if accidents occur. This became devastatingly clear in June 2019 at the Philadelphia Energy Solutions (PES) refinery.
The refinery experienced a catastrophic release of hazardous gases that ignited, leading to a massive fire. Residents were jolted awake in the early morning by three explosions. The most powerful of these was so intense it launched a vessel fragment over 2,000 feet into the air, sending it flying across the Schuylkill River. Miraculously, no one died in the accident, and only five employees sustained minor injuries. The refinery ceased operations shortly after and quickly filed for bankruptcy. Read on for a detailed account of this major industrial disaster on philadelphia.name.
What Happened on the Morning of June 21, 2019?
The Philadelphia Energy Solutions (PES) refinery was a vast complex formed by the merger of two facilities: Girard Point and Point Breeze. It was a key producer of high-quality gasoline and other related products.
On the morning of June 21, 2019, the refinery’s alkylation unit was operating as usual. Around 4:00 AM, liquefied gas (primarily propane mixed with hydrofluoric acid) began leaking from a ruptured pipe at the pump’s outlet. Three operators were managing the unit at the time:
- At 4:01 AM, one operator spotted a vapor cloud rising about 10 feet above the ground and immediately reported it.
- By 4:02 AM, the vapor ignited, triggering a massive fire.
Fortunately, the operators managed to evacuate the hazardous area without injury.
Plant workers then scrambled to contain the blaze. At 4:03 AM, an operator in the remote control room activated the hydrofluoric acid redistribution system, diverting 340,000 pounds of the substance into an isolated tank. Another operator attempted to activate the water cannons at 4:12 AM. These cannons were designed to reduce vapor emissions and help extinguish the flames, but the system failed. It was later discovered that the control system had stopped working at 4:02 AM, and its backup power supply failed just nine seconds later. An operator tried to manually activate the pumps but was thwarted by the intense heat at the scene.
With containment efforts faltering, the first explosion rocked the plant at 4:15 AM, followed by a second just four minutes later. At 4:22 AM, a storage tank containing flammable hydrocarbons (a mixture of butylene, isobutane, and n-butane) ruptured, causing the most powerful explosion. The force of this blast dislodged and propelled vessel fragments weighing 17,000 lbs, 10,000 lbs, and 7,000 lbs. The largest of these fragments was launched clear across the Schuylkill River.
At 4:39 AM, the shift supervisor, donning a fire-resistant suit, bravely entered the unit and successfully activated the water pumps to combat the fire.
By this time, residents living east of the plant had been notified of the fire and advised to shelter in place. The inferno raged for over 24 hours, finally being extinguished at 8:30 AM the following day.
Investigation into the Incident
The primary cause of the explosions and fire at the plant was determined to be a ruptured pipe within the unit. The final report on the incident, published by the U.S. Chemical Safety Board in October 2022, revealed that the pipe, installed in 1973, had suffered extensive corrosion during its operation, leading to its catastrophic failure.
The refinery announced its complete shutdown in June 2019, and a month later, it filed for bankruptcy. This incident reduced the U.S. refining capacity by 2%.
The Refinery’s Future
In 2022, plans for redeveloping the former refinery site began to take shape. After the plant declared bankruptcy, Hilco Redevelopment Partners (HRP) acquired the property. In the spring of 2024, HRP commenced construction on a 300,000-square-foot warehouse at the site. Future plans include over ten additional developments, including a life sciences research campus. This ambitious project is expected to create over 19,000 jobs.
While the closure of the oil refinery has significantly reduced carbon emissions in the city, improving the local environmental situation, the new warehouses and other facilities will lead to increased vehicular traffic, which will also contribute to atmospheric pollution.
Environmental activists had advocated for the refinery’s closure for years, and the group Philly Thrive continues to pressure HRP. They aim to involve the community in redevelopment planning and are pushing for HRP to sign a Community Benefits Agreement. This agreement would ensure that at least a quarter of the new jobs go to local residents and that the new facilities are powered by renewable energy.
Ultimately, the Philadelphia Energy Solutions explosions and fire represent one of Philadelphia’s largest industrial accidents. However, in the long term, they could have positive environmental implications for the city.