Simply put, BLEVEs are extremely dangerous chemical exposure events that occur when containment tanks become highly pressurized and explode, releasing toxic chemicals in a wide area. BLEVE stands for “Boiling Liquid Expanding Vapor Explosion,” a catastrophic event that can lead to community exposure.
BLEVEs came to the forefront of the nation over the weekend as responders raced to contain a massive, compromised storage tank in Garden Grove, California.
How Do BLEVEs Happen?
A BLEVE usually begins with a pressurized tank or vessel containing a liquid that is being stored above its atmospheric boiling point. If the container is heated by fire, damaged by impact, weakened by corrosion, overfilled, or improperly maintained, the vessel may no longer be able to contain the pressure inside.
When the tank fails, the pressure drops almost instantly. The superheated liquid rapidly changes into vapor, expands, and releases stored energy. When the liquid is a flammable compound like hydrogen or methyl methacrylate, the vapor cloud may ignite and create a large fireball.
This is exactly what happened at the Pasadena INEOS plant in 2023 – in that case, a tanker was transferring liquid petroleum gas to the storage tank. Officials pinpointed the source of the accident to a chemical leak due to high pressures.
Why Are BLEVEs So Dangerous?
BLEVEs are dangerous because they result in compound injuries:
- Thermal burns from fireballs, flash fires, or radiant heat
- Blast injuries from pressure waves
- Shrapnel injuries from tank fragments, piping, valves, or nearby structures
- Respiratory injuries from smoke, chemical vapor, or toxic exposure
- Crush injuries from structural collapse or debris
- Psychological trauma after evacuation or explosions,
The U.S. Chemical Safety Board has investigated multiple pressure-vessel and tank explosions where people were killed or injured by both the initial explosion and flying vessel fragments. In the Loy-Lange Box Company explosion in St. Louis, for example, a pressure vessel weighing roughly 2,000 pounds was launched from the facility and landed on a nearby business, killing three people there after killing one worker at the original site.
Recent BLEVE Cases in Houston and Beyond
Pasadena, Texas: INEOS Phenol Explosion and Lawsuit
The BLEVE explosion at the INEOS Phenol facility in Pasadena in 2023 resulted in serious injuries.
A worker, Arturo Jimenez, sued INEOS Phenol and related entities, alleging gross negligence and seeking punitive damages. According to local news, the worker claimed he was thrown to the ground by the blast and that exits he tried to use were not opened during the emergency. The report also said the explosion happened while LPG was being transferred through a hose and that a leak occurred in the tanker.
Garden Grove, California: GKN Aerospace Chemical Tank Emergency
In May 2026, a chemical emergency at a GKN Aerospace facility in Garden Grove, California, forced tens of thousands of residents to evacuate after a tank containing methyl methacrylate overheated. Authorities reported that the tank held roughly 6,000 to 7,000 gallons of the chemical and that officials were concerned about pressure, vapor hazards, and possible explosion.
This was not reported as a completed BLEVE. Rather, it was potentially just moments away from becoming a BLEVE. People reported that firefighters later eliminated the possibility of a catastrophic BLEVE after pressure was relieved, but the emergency still led to more than 50,000 evacuations and a local state of emergency.
The event also produced civil litigation. Two residents filed a class-action lawsuit against GKN Aerospace after the evacuation, seeking compensation tied to the emergency’s impact on residents.
Philadelphia, Pennsylvania: PES Refinery Fire
In 2019, an explosion was reported at the Philadelphia Energy Solutions refinery. According to the Chemical Safety Board, the BLEVE occurred because a pipe elbow ruptured in the refinery’s hydrofluoric acid alkylation unit, releasing process fluid that formed a vapor cloud and caused a large fire and multiple explosions.
The CSB later recommended stronger safeguards for refineries that use hydrofluoric acid alkylation units, including safer design expectations, emergency isolation, and improved process safety oversight.
St. Louis, Missouri: Loy-Lange Pressure Vessel Explosion and $47 Million Settlement
Finally, the Loy-Lange Box Company explerienced a BLEVE explosion in St. Louis in 2017. However, instead of dangerous chemicals, the explosion in St. Louis was due to pressurized water and steam. A massive steam explosion launched a pressure vessel from the facility, killing one worker, critically injuring another, and causing the vessel to land on a nearby business, where three additional people were fatally injured.
The CSB later found that the vessel had serious corrosion and that the company continued operating it despite known leaks and mechanical integrity problems. The civil litigation resulted in a reported $47 million settlement.
Who Can Be Liable After a BLEVE Explosion
Who is liable depends on what caused the container to fail. Like many refinery cases, some of the most common parties include:
- Plant owners and operators
- Tanker-truck or railcar companies
- Chemical manufacturers or distributors
- Maintenance contractors
- Inspection companies
- Equipment manufacturers
- Staffing or training companies
- Property owners
In many BLEVE cases, the resulting explosion occurrs due to a lack of maintenance, failure to adhere to safety protocols or defective valves and other connectors.
Hire a Lawyer for Injuries After a BLEVE Explosion
BLEVEs are rarely freak accidents. What is much more common is that the explosion occurred as a result of a lack of communication, poor maintenance, improper handling or defective products. However, proving that a company failed to maintain its equipment or that products like valves were misused or malfunctioned is highly technical.
Hilda Sibrian has represented clients injured in refinery and industrial accidents and explosions for over 22 years. If you or someone you love was injured as a result of a chemical release or refinery explosion, you need to call an experienced Houston attorney as soon as possible. The Law Offices of Hilda Sibrian serve all of Houston and Texas, including Sugar Land, Missouri City, La Porte, Beaumont, Pasadena, The Woodlands, The Heights, Bellaire, Kingwood, Baytown and of course Houston proper.
Call the Law Offices of Hilda Sibrian today for a free consultation, or fill out our online contact form.
