Sigachi blast is deadliest industrial accident to occur in Telangana & Andhra Pradesh

Hyderabad: The dryer explosion at Sigachi Industries in Pashamylaram, which killed over 35 workers and injured dozens, stands as the deadliest industrial accident in the history of Telangana and Andhra Pradesh, and among the worst in India’s chemical sector.

In past five years, the two states have witnessed several fatal explosions in chemical and pharma manufacturing units.The last major incident took place on August 21, 2024, when 17 workers died and more than 35 were injured in a massive explosion at Escientia Pharma in the Atchutapuram SEZ of Andhra Pradesh. Months before that, in April 2024, four people died and 16 others were injured in an explosion at SB Organics in Sangareddy, Telangana.

A hot oil jacket leaked into the reactor, causing a blast. “The common thread in all these incidents is poor maintenance, unqualified staff, and a complete absence of documented safety protocols,” said K Babu Rao, a retired CSIR scientist who tracked industrial violations in the region for over three decades. “Serious fallout like FIRs, compensation packages, and inquiry committees follow each explosion, but no one attempts to address the root causes.”

Given the spate of fatal accidents, experts have renewed calls to revive a long-delayed plan to form a joint inspection committee tasked with monitoring safety in industrial belts. Proposed in 2023 after repeated complaints from residents near such facilities, “The committee was meant to include officials from the Inspector of Factories, Telangana State Pollution Control Board (TGPCB), and other relevant departments.

The committee was never formed. The plan was shelved after the member secretary was transferred,” confirmed a TGPCB official.Meanwhile, environmentalists who have been flagging concerns about industrial zones like Pashamylaram and Patancheru since the 1990s have reiterated their demand to shift hazardous units away from residential areas. “What’s missing is enforcement,” said structural engineer SP Anchuri.

“Under the Factories Act, hazardous units are required to conduct periodic risk assessments, install emergency relief systems, and train staff in chemical safety.

But most skip drills, fudge documents, and continue hiring under-qualified contract workers.” He added that the Hazardous Chemicals Rules also mandate both on-site and off-site emergency plans and temperature control systems, “but who checks if those exist or are ever updated?”Fire auditor C Andrew, who audited multiple chemical units over 45 years, stressed the need for modern fire suppression systems such as aerosol suspension and blanketing.

“Most of these plants are decades old. There must be third-party safety audits every year. Newer facilities should adopt compartmentalisation, solvent storage and electrical panels must be on separate floors. That alone could prevent tragedies like these.

”................Industrial accidents in Telangana & Andhra Pradesh in past 5 years:August 2024: Escientia Pharma, Atchutapuram: MTBE vapour leaked during reactor operations & ignited on contact with an electrical panel, killing 17 & injuring over 35 during lunch hourApril 2024: SB Organics, Sangareddy: A hot oil jacket leaked into a reactor causing a violent blast; 4 workers died & 16 injured. The plant had no cooling system or trained staffJuly 2024: Vasant Chemicals, Atchutapuram: A benzophenone reactor exploded due to suspected thermal or pressure failure, killing a contract worker May 2020: LG Polymers, Visakhapatnam: Styrene gas leak from a failed refrigeration system created a toxic cloud, killing 11 & hospitalising hundreds; thousands exposedMay 2020: Biofuel Plant, Zaheerabad: A reactor exploded during welding repair due to flammable gas in the tank, killing 2 workers & injuring 1August 2022: Hindys Labs, Nalgonda: A reactor exploded during batch processing, killing 1 & injuring 6; this was the fourth such incident at the unit in two yearsJune 2022: Gowliguda, Hyderabad: Residual resin reacted with water during tank cleaning, causing a chemical blast that killed 1 worker & injured 2

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