Seven workers were transported to the hospital as a precaution after zirconium tetrachloride was released at ATI Millersburg Operations in Albany Sept. 9.
United Steelworkers (USW) Local 6163 represents workers at the Albany facility, which is part of ATI’s Specialty Alloys and Components unit. That division of ATI produces specialized metal alloys using zirconium, hafnium, and niobium that are used in nuclear, space, medical, and electronic markets.
Zirconium tetrachloride was released through a safety valve on a furnace in the facility’s chemical operations area, an ATI spokesperson said. The valve was triggered by a sudden increase in heat, ATI said.
Zirconium tetrachloride is a white powdery substance. When it reacts with moisture, it can produce hydrogen chloride gas. Inhaling zirconium tetrachloride or hydrogen chloride gas causes lung irritation, coughing, and shortness of breath. More severe or sustained exposures can result in a build-up of fluid in the lungs.
USW subdistrict director Ron Rodgers said the seal worked as designed to prevent damage to the system.
The facility has a scrubber system and large fans to help clear the gas. As designed, the fans blew some of the gas into the atmosphere, Rodgers told the Labor Press by email.
“Normally, the gas would simply rise and dissipate. On the day of the incident, there was a bit of sustained wind and a cold front which caused some of the gas to linger at a lower level,” Rodgers explained.
Albany Fire Department responded with a hazmat unit.
“Our team acted quickly to redirect the release back into the fume collection system, and the involved furnace was immediately shut down,” ATI said.
Seven people, all USW Local 6163 members, were exposed to hydrogen chloride gas outside of the building and were sent to the hospital as a precautionary measure. Six went via ambulance, one went later via company vehicle.
No one required any medical treatment, Rodgers said. ATI said all the workers were released from the hospital within hours and had returned to work since the incident.
There were also people inside the building, but they were wearing powered air-purifying respirators, Rodgers said.
