On 3 December 1984, over 500,000 people in the vicinity of the Union Carbide India Limited pesticide plant in Bhopal, Madhya Pradesh, India, were exposed to the highly toxic gas methyl isocyanate, in what is considered the world's worst industrial disaster, as well as the largest chemical disaster in Indian history. A government affidavit in 2006 stated that the leak caused approximately 558,125 injuries, including 38,478 temporary partial injuries and 3,900 severely and permanently disabling injuries. Estimates vary on the death toll, with the official number of immediate deaths being 2,259. Others estimate that 8,000 or more died from gas-related diseases. In 1989, Union Carbide Corporation (UCC) of the United States paid $470 million (equivalent to $1.06 billion in 2025) to settle litigation stemming from the disaster.
The owner of the factory, Union Carbide India Limited (UCIL), was a publicly-traded company which was majority-owned and controlled by the UCC, while the remaining 49.1 percent stake was held by the Indian public and Indian government-controlled banks. In 1994, UCC sold its stake in UCIL to Eveready Industries India Limited (EIIL), which subsequently merged with McLeod Russel (India) Ltd. Eveready ended clean-up on the site in 1998, when it terminated its 99-year lease and turned over control of the site to the state government of Madhya Pradesh. Dow Chemical Company purchased UCC in 2001, seventeen years after the disaster.
Civil and criminal cases filed in the United States against UCC and Warren Anderson, chief executive officer of the UCC at the time of the disaster, were dismissed and redirected to Indian courts on multiple occasions between 1986 and 2012, as the US courts focused on UCIL being a standalone entity of India. Civil and criminal cases were also filed in the District Court of Bhopal, India, involving UCC, UCIL, and Anderson. In June 2010, seven Indian nationals who were UCIL employees in 1984, including the former UCIL chairman Keshub Mahindra, were convicted in Bhopal of causing death by negligence and sentenced to two years' imprisonment and a fine of about $2,000 each, the maximum punishment allowed by Indian law. All were released on bail shortly after the verdict. An eighth former employee was also convicted, but died before the judgement was passed.
Background
The UCIL factory was built in 1969 to produce the pesticide Sevin (UCC's brand name for carbaryl) using methyl isocyanate (MIC) as an intermediate. An MIC production plant was added to the UCIL site in 1979. The chemical process employed in the Bhopal plant had methylamine reacting with phosgene to form MIC, which was in turn reacted with 1-naphthol to form the final product, carbaryl. Another manufacturer, Bayer, also used this MIC-intermediate process at the chemical plant once owned by UCC at Institute, West Virginia in the United States.
After the Bhopal plant was built, other manufacturers (including Bayer) produced carbaryl without MIC, though at a greater manufacturing cost. UCIL's process differed from the MIC-free routes used elsewhere, in which the same raw materials were combined in a different manufacturing order, with phosgene initially reacting with 1-naphthol to form a chloroformate ester, which was later reacted with methylamine. In the early 1980s, although the demand for pesticides had fallen, production continued leading to an accumulation of unused MIC at the Bhopal site.
Earlier leaks
In 1976, two local trade unions complained of pollution within the plant. In 1981, a worker was accidentally splashed with phosgene as he was carrying out a maintenance job of the plant's pipes. In a panic, he removed his gas mask and inhaled a large amount of toxic phosgene gas, leading to his death 72 hours later. Following these events, journalist Rajkumar Keswani began investigating and published his findings in Bhopal's local paper Rapat, in which he urged "Wake up, people of Bhopal, you are on the edge of a volcano."
In January 1982, a phosgene leak exposed 24 workers, all of whom were admitted to a hospital. None of the workers had been ordered to wear protective equipment. One month later in February 1982, an MIC leak affected 18 workers. In August 1982, a chemical engineer came into contact with liquid MIC, resulting in burns over 30% of his body. In October 1982, there was another MIC leak. In attempting to stop the leak, the MIC supervisor suffered severe chemical burns and two other workers were severely exposed to the gases. During 1983 and 1984, there were leaks of MIC, chlorine, monomethylamine, phosgene, and carbon tetrachloride, sometimes in combination.
Leakage and its effects
Liquid MIC storage
The Bhopal UCIL facility housed three underground 68,000-litre (18,000-US-gallon) liquid MIC storage tanks: E610, E611, and E619. In the months leading up to the December leak, liquid MIC production was in progress and being used to fill these tanks. UCC safety regulations specified that no one tank should be filled more than 50% (about 30 tons) with liquid MIC. Each tank was pressurized with inert nitrogen gas. This pressurization allowed liquid MIC to be pumped out of each tank as needed and also kept impurities and moisture out of the tanks.
In late October 1984, tank E610 lost the ability to effectively contain most of its nitrogen gas pressure, which meant that the liquid MIC contained within could not be pumped out. At the time of this failure, tank E610 contained 42 tons of liquid MIC. Shortly after this failure, MIC production was halted at the Bhopal facility, and parts of the plant were shut down for maintenance. Maintenance included the shutdown of the plant's flare tower so that a corroded pipe could be repaired. With the flare tower still inoperable, production of carbaryl was resumed in late November using MIC stored in the two tanks still in service. An attempt to re-establish pressure in tank E610 on 1 December failed, so the 42 tons of liquid MIC contained within still could not be pumped out of it.
Gas leak
By early December 1984, most of the plant's MIC related safety systems were malfunctioning and many valves and lines were in poor condition. In addition, several vent gas scrubbers had been out of service, as well as the steam boiler intended to clean the pipes. During the late evening hours of 2 December 1984, water was believed to have entered tank E610 via a side pipe during attempts to unclog it. The tank still contained the 42 tons of MIC that had been there since late October. The introduction of water into the tank resulted in a runaway exothermic reaction, which was accelerated by contaminants, high ambient temperatures, and various other factors such as the presence of iron from corroding non-stainless steel pipelines. The pressure in tank E610, although initially nominal at 14 kilopascals (2 psi) at 10:30 p.m., reached 70 kilopascals (10 psi) as of 11 p.m. Two different senior refinery employees assumed the reading was instrumentation malfunction. By 11:30 p.m., workers in the MIC area were feeling the effects of minor exposure to MIC gas and began to look for a leak. One was found by 11:45 p.m. and reported to the MIC supervisor on duty at the time. The decision was made to address the problem after a 12:15 a.m. tea break, and in the meantime, employees were instructed to continue looking for leaks. The problem was discussed by MIC area employees during the break.
When the tea break concluded at 12:40 a.m., the reaction in tank E610 escalated to a critical state at a rapid speed within five minutes. Temperatures in the tank were off the scale beyond 25 °C (77 °F), and the pressure in the tank was indicated at 280 kilopascals (40 psi). One employee witnessed a concrete slab above tank E610 crack as the emergency relief valve burst open, and pressure in the tank continued to increase to 380 kilopascals (55 psi), despite atmospheric venting of toxic MIC gas having begun. Direct atmospheric venting should have been prevented or at least partially mitigated by at least three safety devices which were malfunctioning, not in use, insufficiently sized, or otherwise rendered inoperable:
- A refrigeration system meant to cool tanks containing liquid MIC had been shut down in January 1982 and the freon had been removed in June 1984. Since the MIC storage system assumed refrigeration, its high temperature alarm, set to sound at 11 °C (52 °F) had long since been disconnected, and tank storage temperatures ranged between 15 °C (59 °F) and 40 °C (104 °F)
- A flare tower to burn the MIC gas as it escaped, which had had a connecting pipe removed for maintenance, was improperly sized to neutralise a leak of the size produced by tank E610.
- A vent gas scrubber which had been deactivated at the time and was in 'standby' mode, and similarly had insufficient caustic soda and power to safely stop a leak of the magnitude produced.
About 30 tonnes of MIC escaped from the tank into the atmosphere in 45 to 60 minutes. This would increase to 40 tonnes within two hours. The gases were blown in a southeast direction over Bhopal.
A UCIL employee triggered the plant's alarm system at 12:50 a.m. as the concentration of gas in and around the plant became difficult to tolerate. Activation of the system triggered two siren alarms: one that specifically sounded inside the UCIL plant itself and a second directed to the exterior which would alert the general public and the city of Bhopal. The two siren systems had been decoupled from one another in 1982, so that it was possible to leave the factory warning siren on while the public one remained inactive. This is what had occurred; the public siren briefly sounded at 12:50 a.m. and was quickly turned off, as per company procedure meant to avoid alarming the public around the factory over inconsequential leaks. Workers, meanwhile, evacuated the UCIL plant, travelling upwind.
Bhopal's superintendent of police was informed via telephone by a town inspector that residents of the neighbourhood of Chola (about 2 km from the plant) were fleeing a gas leak at approximately 1 a.m. Calls to the UCIL plant by police between 1:25 and 2:10 a.m. elicited assurances twice that "everything is OK", and on the last attempt made, "we don't know what has happened, sir". With the lack of timely information exchange between UCIL and Bhopal authorities, the city's Hamidia Hospital was first told that the gas leak was suspected to be ammonia, then later phosgene. Finally, they received an updated report that it was "MIC" (rather than "methyl isocyanate"), which hospital staff had never heard of, had no antidote for, and knew no immediate information about.
The MIC gas leak from tank E610 stopped at approximately 2 a.m. Fifteen minutes later, the plant's public siren was sounded for an extended period of time after having been quickly silenced an hour and a half earlier. Some minutes after the public siren sounded, a UCIL employee walked to a police control room to both inform them of the leak (their first acknowledgement that one had ever occurred in the first place), and said that the leak had been plugged. Most city residents who were exposed to the MIC gas were first made aware of the leak by exposure to the gas itself, or by opening their doors to investigate commotion, rather than having been instructed to shelter in place or to evacuate before the arrival of the gas in the first place.
Acute effects
The initial effects of exposure were coughing, severe eye irritation, a feeling of suffocation, burning in the respiratory tract, blepharospasm, breathlessness, stomach pains, and vomiting. People alerted by these symptoms fled from the plant. Those who ran inhaled more than those in vehicles. Owing to their height, children and other residents of shorter stature inhaled higher concentrations, as methyl isocyanate gas is approximately twice as dense as air and in an open environment has a tendency to fall toward the ground.
Thousands of people had died by the following morning. Primary causes of deaths were choking, reflexogenic circulatory collapse, and pulmonary oedema. Findings during autopsies revealed changes not only in the lungs but also cerebral oedema, tubular necrosis of the kidneys, fatty degeneration of the liver, and necrotising enteritis. The individuals who did not die suffered from cancer, blindness, loss of livelihood, and financial strain.
Gas cloud composition
Apart from MIC, based on laboratory simulation conditions, the gas cloud most likely also contained chloroform, dichloromethane, hydrogen chloride, methylamine, dimethylamine, trimethylamine, and carbon dioxide that was either present in the tank or was produced in the storage tank when MIC, chloroform, and water reacted. The gas cloud, composed mainly of materials denser than air, stayed close to the ground and spread in a southeast direction affecting the nearby communities. The chemical reactions may have produced a liquid or solid aerosol.
Laboratory investigations by CSIR and UCC scientists failed to demonstrate the presence of hydrogen cyanide.
In the immediate aftermath, the plant was closed to outsiders (including UCC) by the Indian government, which subsequently failed to make data public, contributing to the confusion. The initial investigation was conducted entirely by the Council of Scientific and Industrial Research (CSIR) and the Central Bureau of Investigation. The UCC chairman and CEO Warren Anderson, together with a technical team, immediately travelled to India. Upon arrival, Anderson was placed under house arrest and urged by the Indian government to leave the country within 24 hours. Union Carbide organized a team of international medical experts, as well as supplies and equipment, to work with the local Bhopal medical community, and the UCC technical team began assessing the cause of the gas leak.
The health care system immediately became overloaded. In the severely affected areas, nearly 70% of doctors were underqualified. Medical staff were unprepared for the thousands of casualties. Doctors and hospitals were not aware of proper treatment methods for MIC gas inhalation.