Bharuch: Five workers were killed and five others injured after a powerful explosion ripped through a chemical manufacturing unit in Gujarat’s Bharuch district late on Friday, officials said on Saturday. The blast at SynZeal Pharmachem in the Saykha industrial area also triggered a leak of methylene dichloride (MDC) gas.

The explosion occurred at around 10 pm during a hydrogenation process at the company’s facility in the Saykha Gujarat Industrial Development Corporation (GIDC) area in Vagra taluka.

According to officials, the blast was powerful enough to rupture the reactor tank and scatter machinery parts across the premises. The incident prompted a response from the police, the Gujarat Pollution Control Board (GPCB) and the Directorate of Industrial Safety and Health (DISH).

Bharuch Sub-Divisional Magistrate Manisha Manani said the company, which was established in Saykha around a year ago, manufactures pharmaceutical intermediates. Superintendent of Police Akshyaraj Makwana confirmed that five workers had died and five others had sustained injuries.

The cause of the explosion remains under investigation, with officials examining the circumstances surrounding the industrial process and the subsequent gas leak.

Explosion during hydrogenation process

The blast took place while a hydrogenation process was reportedly under way at SynZeal Pharmachem’s manufacturing facility.

Hydrogenation is a chemical process in which hydrogen is used in a reaction to alter the composition of a substance. It is employed in several industrial and pharmaceutical manufacturing operations.

The explosion reportedly damaged the reactor tank, with machinery parts scattered across the factory premises. The force of the blast raised concerns about the conditions inside the unit at the time of the incident.

Officials said the explosion also triggered a leak of methylene dichloride, commonly known as MDC. The chemical is used as an industrial solvent and can pose health risks if people are exposed to dangerous concentrations.

An official from the Directorate of Industrial Safety and Health said the gas leak followed the explosion during the hydrogenation process.

The precise sequence of events leading to the blast has not yet been established. Investigators are expected to examine the reactor, the operating conditions and other relevant evidence to determine what caused the explosion.

Five workers killed in Bharuch blast

Bharuch Superintendent of Police Akshyaraj Makwana confirmed that five workers lost their lives in the incident.

The deceased were identified as Jaydeep Maheshbhai Patel and Bhavik Dilipkumar Vasava, both from Amod in Bharuch district; Vrund Talaviya from Talala in Gir Somnath district; and Aniket Harilal Gautam and Arjunkumar Ramsingh Gautam, who were natives of Uttar Pradesh.

The deaths have brought attention to the risks faced by workers in chemical manufacturing facilities, where industrial processes can involve hazardous substances, specialised equipment and potentially dangerous operating conditions.

Officials have not yet disclosed detailed information about the workers’ duties at the time of the explosion or the circumstances in which each person was fatally injured.

The investigation will need to establish how the reactor failed, whether safety systems were functioning as intended and whether any operational or technical factors contributed to the incident.

Five injured workers receiving treatment

Five other workers were injured in the explosion and are undergoing treatment, Makwana said.

The injured were identified as Pavankumar Ramsingh Gautam, Mausamkumar Ramsevak Yadav, Shivdayal Ramavatar Yadav, Pratik Pravin Prajapati and Priyanshu Bahadurlal. They were reported to be from Bihar and Uttar Pradesh.

Officials did not provide detailed information about the severity of their injuries or their medical condition.

The leak of MDC gas has also raised questions about possible exposure risks at the facility. However, the available information does not establish whether the injured workers sustained injuries directly from the blast, chemical exposure or a combination of factors.

Further information from medical authorities and investigators may clarify the nature of the injuries and the conditions faced by workers during the incident.

Authorities investigate chemical leak

Officials from the Gujarat Pollution Control Board, the Directorate of Industrial Safety and Health and the police reached the site after the explosion.

Their investigation is expected to focus on the cause of the blast, the damage to the reactor tank and the circumstances that led to the release of MDC gas.

The industrial safety department is responsible for examining workplace safety and compliance with applicable industrial regulations. The pollution control board may also assess the environmental implications of the chemical leak and determine whether additional measures are required.

The presence of multiple agencies reflects the different aspects of the incident, including worker safety, potential chemical exposure and the possibility of environmental contamination.

Officials have not announced a final finding on the cause of the explosion. Any determination of responsibility or safety violations would depend on the outcome of the investigation.

Chemical manufacturing safety under scrutiny

The incident has once again drawn attention to industrial safety in chemical manufacturing units.

Facilities producing pharmaceutical intermediates often use chemical reactors and other specialised equipment to carry out controlled reactions. These operations require appropriate operating procedures, maintenance, monitoring and emergency response systems.

A reactor failure can have serious consequences, particularly when it occurs during a process involving hazardous chemicals or pressurised equipment.

The Bharuch explosion also highlights the importance of ensuring that workers are adequately trained to handle industrial emergencies and that factories have procedures to respond to fires, explosions and chemical leaks.

However, the cause of the SynZeal Pharmachem blast has not been established, and it would be premature to attribute the incident to a specific equipment failure, procedural lapse or regulatory violation before investigators complete their assessment.

The findings could help determine whether changes to operating procedures, equipment maintenance or safety measures are necessary.

Investigation continues after fatal explosion

SynZeal Pharmachem’s facility in the Saykha GIDC area was established around a year ago and manufactures pharmaceutical intermediates, according to Bharuch Sub-Divisional Magistrate Manisha Manani.

The explosion has left five workers dead and five others injured, while authorities continue to investigate the circumstances surrounding the incident.

The immediate focus is on determining what caused the reactor tank to rupture and how the explosion led to the release of methylene dichloride gas. Investigators will also examine the plant’s safety arrangements and the sequence of events before and after the blast.

For the families of the deceased workers, the investigation is expected to provide answers about the circumstances that led to the loss of their loved ones. The condition of the injured workers and any further findings from the authorities will also be closely watched.

The incident underscores the serious consequences that industrial accidents can have on workers and their families. A clear account of the cause, supported by the findings of the relevant authorities, will be essential to establishing what happened at the Bharuch chemical unit and whether further action is required.