Chemical Factory Explosion Rocks Industrial Zone In India, Workers Evacuated, Toxic Leak Feared After Blast

Mumbai, India— A powerful explosion ripped through a chemical processing plant on the outskirts of Mumbai around 7:20 a.m., shattering windows a kilometer away and forcing the evacuation of more than 500 workers and nearby residents.

The blast hit Unit 3 of the plant, where solvents were being mixed for industrial cleaning products, according to workers. A reactor vessel ruptured. The force blew off a section of roof and sent a plume of acrid yellow smoke into the air. Secondary fires broke out in storage drums.

Four workers inside the unit suffered burns and were taken to KEM Hospital. Two are in critical condition. A shift supervisor said, "We smelled gas for ten minutes before, we reported it, then the whole shed lifted." He said alarms sounded late.

The Maharashtra Industrial Development Corporation ordered a full evacuation of the Taloja industrial zone. Loudspeakers told residents in two nearby villages to stay indoors and cover their faces. The district collector said air quality teams were deployed to check for chlorine and benzene traces.

Fire tenders from four stations arrived but struggled to get close due to heat and chemical drums popping. They used water curtains to keep the fire from reaching a larger tank farm 50 meters away. That tank farm holds highly flammable materials.

The plant, owned by a mid-size private chemical firm, has faced two safety notices this year, records show. One notice in April cited poor pressure valve maintenance. Another in July flagged inadequate worker training on leak response. The company has not commented.

The state pollution control board said initial air readings showed elevated volatile compounds but not at lethal levels. Still, officials warned people with respiratory issues to leave. Schools within three kilometers were shut for the day.

Police registered a case for negligent handling of hazardous substances. The labor department said it will seize maintenance logs and interview the safety officer, who was not on site at the time of the blast.

Smoke was still rising at noon. The cause remains undetermined. Investigators are waiting for the site to cool before entering the reactor area.