Explosion Injures Five at ExxonMobil Baytown Refinery – December 23, 2021

Incident Details

• Date: December 23, 2021

• Location: Baytown, Texas (Harris County)

• Facility: ExxonMobil Baytown Refinery

• Company: ExxonMobil

• Type of Incident: Explosion and fire

• Known Cause: Believed to be related to a vapor cloud ignition; full report pending

• Injuries: 5 workers injured, including burns and trauma

• Fatalities: None reported

• Environmental Impact: Localized air pollution; flaring visible for several hours

• Community Impact: No evacuation ordered, but nearby residents reported structural shaking and noise complaints

• Emergency Response: Plant emergency team and local fire units responded; fire contained by morning

• Investigations: OSHA investigation launched; internal company review conducted

• Legal Action: Lawsuits filed by two injured workers seeking over $10 million in damages

• Estimated Financial Losses: Not publicly disclosed; partial shutdown of operations

• Regulatory History: ExxonMobil Baytown has a long history of environmental and safety violations, including a 2019 Clean Air Act judgment

Incident Report

In the early hours of December 23, 2021, an explosion rocked the ExxonMobil Baytown refinery, one of the largest petrochemical complexes in the United States. Just before 1 a.m., a sudden blast occurred in the refinery’s hydrotreater unit, sending shockwaves through the surrounding area and injuring five workers.

Emergency crews responded swiftly as flames and smoke were reported from within the unit. While the fire was contained before sunrise, the noise and concussion from the explosion were felt as far as several miles away. Nearby residents reported rattling windows and loud booms in the middle of the night, leading to fears of a larger catastrophe.

Though no fatalities were recorded, the injuries sustained were serious. Two of the injured workers have since filed lawsuits against ExxonMobil, alleging gross negligence and failure to provide a safe working environment. Both suffered burns and long-term trauma-related injuries.

Initial reports suggest a vapor cloud buildup as the possible cause, a recurring risk in aging refining infrastructure. OSHA launched a formal investigation, and internal reviews by ExxonMobil began shortly after. However, public skepticism remained high given the facility's regulatory history, including a 2019 federal ruling in which the company was ordered to pay $19.95 million for Clean Air Act violations.

The Baytown explosion is a stark reminder that even the most advanced and well-resourced operations in the industry are not immune to systemic safety failures. And in a city where refineries sit alongside schools and neighborhoods, the margin for error continues to be far too narrow.