Sulfuric Acid Release: Structural Failure at Texas Terminal
Location: Channelview, Texas, United States
Summary of the Incident
On December 27, 2025, a release of approximately one million gallons of spent sulfuric acid occurred at the BWC Terminals facility in Channelview, Texas, along the Houston Ship Channel. The incident began around 1:40 a.m. when a catwalk structure collapsed, falling onto and rupturing a 6-inch sulfuric acid supply line connected to a 25,000-barrel storage tank.
The facility is a bulk liquid storage terminal that handles hazardous chemicals. While the majority of the release was captured by the facility's secondary containment system, an undetermined amount of acid bypassed containment and entered the adjacent ship channel. Emergency responders evaluated over 40 individuals at the scene, including crew members from nearby vessels, and two individuals were hospitalized with respiratory issues.
Speculation on Cause
While the immediate cause was the impact of the falling catwalk, the root cause likely lies in Mechanical Integrity (MI) deficiencies regarding structural steel. In a corrosive environment like a sulfuric acid terminal, structural components (catwalks, pipe racks, supports) are highly susceptible to accelerated corrosion from acid vapors. It is possible that the catwalk's structural supports had thinned significantly over time due to this exposure, eventually failing under normal load. Additionally, the facility may have lacked a robust inspection program for "non-process" structures (like catwalks) compared to the rigorous inspections typically applied to tanks and piping.
Relevant Industry Standard: API 570
API 570: Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping Systems
API 570 covers the inspection and management of in-service piping systems.
How it applies: While API 570 primarily focuses on the pipe itself, it requires External Visual Inspections which include assessing the condition of the piping system and its environment.
Prevention: A rigorous application of API 570 would include identifying "threats" to the piping system. An inspector following the code should look for "impact damage" risks or deteriorating structures overhead that could pose a hazard to the active line. Had the external visual inspection program included a review of the structural integrity of the catwalk (or flagged it as a potential dropped-object hazard due to visible corrosion), the risk could have been mitigated before the collapse occurred.
Sources of Information
Click2Houston (KPRC) – 1M gallons of sulfuric acid spilled, some into ship channel from Channelview chemical leak (Dec 27, 2025)
Maritime Executive – Sulfuric Acid Spills Into Houston Ship Channel (Dec 28, 2025)
EntirelySAFE – Catastrophic Sulfuric Acid Leak at BWC Terminals (Dec 28, 2025)