Lab Lesson Learned:

Researcher Dies After Lab Fire

UCLA Research Assistant Burned in Incident with Tert-Butyl Lithium

A research assistant at the University of California, Los Angeles (UCLA), department of chemistry and biochemistry died on Jan. 16 from injuries sustained in a laboratory fire which occurred in December, 2008.

“UCLA had told its researchers that they could work during the holiday break shut down for ‘critical research needs,’ and on 29 December the Research Assistant was working with a bottle of t-butyl lithium dissolved in pentane. While using a syringe to withdraw a quantity of the reagent, she reportedly pulled the plunger all the way out, introducing air and creating a flash fire.

‘Every single major university will have to look at their policies regarding the handling of this type of material and will make adjustments accordingly,” Russ Phifer, who chairs the American Chemical Society's chemical safety committee, reported to Chemistry World. “Some may restrict the use of pyrophoric materials, or put protocols in place that require additional training for researchers.’”

http://www.rsc.org/chemistryworld/News/2009/January/23010903.asp

A pyrophoric material can spontaneously ignite in air. The word is derived from Greek for "fire-bearing." Many pyrophoric materials are also water reactive, reacting vigorously with water or high humidity, often igniting upon contact. The spontaneous ignition in air can take place at a temperature of 54.4 degrees C (130 degrees F) or below.

Examples of pyrophoric materials include organometallic reagents such as alkyllithiums, alkylzincs, alkylmagnesiums (Grignards) and some finely divided metal powders. Specific examples include diborane (B₂H₆), diethylzinc (Zn(CH₂CH₃)₂), tert-butyllithium (LiC(CH₃)₃) and diphosphine (P₂H₄). Pyrophoric materials are provided to the laboratories in inert but flammable organic solvents.

These highly reactive substances are quite useful in the synthesis of organic chemicals, but special training is required to store and handle these materials safely. Most typically, pyrophoric materials are manipulated in an inert (unreactive) atmosphere of nitrogen or argon using specialized glassware.

The accident at UCLA was preventable. Universities must now conduct an evaluation of chemistry lab safety procedures to prevent recurrence.

UCLA reported that the research assistant was wearing nitrile gloves, safety glasses, and a synthetic sweater with no lab coat. When the fire ignited the gloves and the sweater, she sustained second and third degree burns over 40 per cent of her body and was immediately hospitalized. UCLA was notified on 16 January that she had died of her injuries.

Synthetic materials such as acetate, nylon, polyester, and rayon should not be worn when working with pyrophoric materials. The Research Assistant was wearing a polyester sweater without a lab coat.

Various pyrophoric chemicals are used at Georgetown University. Since these materials react with water, oxygen, or both, their exposure to the atmosphere must be minimized. Using syringe techniques or using a Cannula for larger scale requirements can be managed with effective equipment and techniques.

Technical Bulletin

Lesson Learned

To avoid tragic events such as the one described above the following suggestions are presented:

· Develop drills for laboratory personnel to handle hazardous situations that require immediate, decisive response. Rehearse these responses, so that no questions remain during an actual emergency.

o Example: An unscheduled announcement where lab personnel, in the midst of work activities are directed to respond to an incident where a fellow worker is on fire. Determine the rapid decisions that must be made from where workers are located (e.g., direct worker to safety shower, activate fire extinguisher, use drench hose, combination of actions). Evaluate the effectiveness of the decisions and the time of response. Provide feedback to improve the response and to identify gaps.

· Establish detailed written procedures for handling pyrophoric so that their handling is performed in a consistent manner and hazards are properly controlled. Standard Operating Procedures (SOPs) and training are essential for this level of hazard. Contact EH&S for assistance.

· After identifying gaps, purchase additional items that may be used in conjunction with existing measures. For example, drench hoses (often dual purpose hoses with eyewash systems) with sufficient length may be mounted near sinks and used in the event that a person’s clothing catches fire (contact EH&S for more information).

· Always wear required personal protective equipment (protective eyewear, safety gloves, a fully-buttoned knee-length lab coat, and any other personal protective PPE that are required by the SOPs). EH&S recommends that a flame-resistant lab coat be worn when working with pyrophorics.

Flame Resistant: The property of a material whereby flaming combustion is prevented, terminated, or inhibited following application of a flaming or nonflaming source of ignition, with or without subsequent removal of the ignition source (29 CFR § 1910.269(l)(6)(iii)).

Contact EH&S for more information on flame-resistant lab coats.

· Never work alone with extremely hazardous materials.

· Keep the hood sash at the proper height and, if procedures allow, closed when leaving chemicals or experiments unattended. If unable to work with the sash of the fume hood pulled down to 18”, wear a face shield to add protection from splashes.

· Assess research activities on a continual basis to ensure the hazards posed are adequately identified, evaluated, and controlled. Complacency can occur once the primary focus of the research has been completed.

· Minimize fire hazards within the hood by removing all unnecessary materials (especially containers of wastes or solvents) when conducting experiments, ensuring that combustible materials (e.g., cleaning wipes) are isolated from pyrophoric materials.

Lawrence Livermore National Laboratories in 2003 Fume hood after a fire involving tris(trimethylsilyl) phosphine (TTMSP), a pyrophoric liquid, at the National Renewable Energy Laboratory. (Lawrence Livermore National Lab Lesson Learned August 8, 2003; LL-2003-LLNL -20)

· Powdered lime can be used to completely smother and cover any spill that occurs. A container of powdered lime should be kept within arm’s length when working with pyrophoric material.

· Do not re-use syringes involved with procedures involving pyrophoric materials.

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