Understanding Polymerization: A Conversation with Bobby Salvesen and Mike Monaco
I sat down with Bobby Salvesen and Mike Monaco to talk about polymerization—a process that’s all around us but can turn hazardous if not properly managed. What started as a simple chemistry discussion quickly turned into an eye-opening conversation about the dangers lurking behind this common reaction.
What is Polymerization?
“Think of polymerization like building with Lego bricks,” Bobby explained. “Monomers are the individual bricks, and when they link up, they form long chains called polymers.” These polymers are everywhere—in plastics, textiles, and even some medical supplies.
But while the science sounds straightforward, the reaction itself can be anything but. “Polymerization can get out of hand fast,” Mike added. “And when it does, it can go from a manageable process to a full-blown hazmat situation.”
The Triggers and Risks of Uncontrolled Polymerization
Polymerization can be initiated through heat, pressure, or chemical catalysts. Once it starts, the reaction releases energy—sometimes a lot of it. “The problem,” Bobby pointed out, “is that some polymerization reactions are exothermic, meaning they release heat. If you don’t control that heat, things can spiral fast.”
Mike nodded. “Take a look at past incidents—like the 2002 Freeport, Texas, incident where a railcar ruptured due to uncontrolled polymerization. Or even the Bhopal disaster, where an unintended polymerization reaction played a major role in the catastrophe.”
Both emphasized that in hazardous material response, being able to recognize when polymerization is happening—or about to happen—can mean the difference between a controlled situation and a runaway chemical disaster.
How to Identify and Respond to a Polymerization Event
“So what are the warning signs?” I asked.
“Heat buildup is a big one,” Mike answered. “If you have a material that’s supposed to be stable but its temperature is rising for no apparent reason, that’s a red flag.”
“Pressure buildup, too,” Bobby added. “Especially in sealed containers. If you’re dealing with monomers in storage, and you notice bulging drums or tanks, you’re looking at a potential polymerization event.”
In hazmat response, tools like thermal imaging cameras can help detect temperature increases before things get critical.
The Role of Inhibitors: A Thin Line Between Stability and Chaos
“That’s where inhibitors come in,” Bobby explained. “They’re chemicals added to monomers to keep them from polymerizing too soon. Think of them like a babysitter making sure the kids don’t run wild. But here’s the catch—those inhibitors don’t last forever.”
“Exactly,” Mike agreed. “If the monomers are stored too long or exposed to the wrong conditions, the inhibitors break down, and suddenly you have a material that’s itching to polymerize on its own. That’s when you get into trouble.”
This is why hazmat teams and industrial facilities monitor inhibitor levels closely. The U.S. Department of Transportation mandates that monomers be transported with proper inhibitors, but once those chemicals start to degrade, the risk climbs fast.
Lessons from Past Incidents
We circled back to real-world cases where polymerization turned into a dangerous event. “Take Freeport, Texas,” Bobby recalled. “A railcar carrying monomers experienced an uncontrolled reaction because of an inhibitor failure. The result? A violent rupture, releasing hazardous materials and putting responders in serious danger.”
Mike added, “Or the Bhopal disaster—while that wasn’t solely a polymerization issue, runaway reactions played a huge role in escalating the catastrophe. It just shows that when you have reactive chemicals involved, you have to be prepared for anything.”
Safety Protocols: How Do You Stay Ahead?
“So how do hazmat teams and industries prevent these incidents?” I asked.
“Monitoring is key,” Bobby answered. “Temperature, pressure, inhibitor levels—you have to track all of it.”
“And education,” Mike added. “Responders need to know what they’re dealing with. Safety Data Sheets (SDS), the Emergency Response Guidebook (ERG)—these are lifesavers in the field.”
They also emphasized a proactive approach. “If you see signs of polymerization, don’t wait,” Bobby warned. “If a container is heating up or swelling, you need to act before it goes critical. That might mean cooling it down, venting pressure, or evacuating if it’s too far gone.”
Final Thoughts: What Can We Learn?
“At the end of the day, it’s about knowing what you’re working with,” Mike said. “Polymerization is an everyday process, but when it happens out of control, it becomes a serious hazard.”
Bobby nodded. “And it’s not just about hazmat teams—anyone handling chemicals needs to understand these risks. Whether you’re in industrial manufacturing, transportation, or emergency response, knowing the warning signs can prevent a disaster.”
Our conversation made one thing crystal clear: polymerization isn’t just a chemistry lesson. It’s a real-world hazard that demands respect, attention, and the right safety measures. If you’ve had experiences dealing with polymerization in the field, share your insights in the comments below. Let’s keep the discussion going and ensure we all stay safe out there.