At CASS, safety is paramount. Protecting our employees, the local community, and the environment drives every decision we make. That’s why we’ve made the firm commitment to never use chlorine gas in our processes, despite its prevalence in the secondary aluminum industry. While some secondary aluminum manufacturers still rely on chlorine gas or chlorine-containing fluxes in their processes, this is a risk that CASS will never take.

Chlorine: A Highly Toxic and Corrosive Gas

Chlorine is well-known for its lethal potential. In high concentrations and under specific conditions, chlorine can pose a severe hazard to the local community. Exposure to this highly toxic, corrosive substance can result in severe respiratory issues, lung damage, and even death. It is critical to note the CDC emphasizes that there is no antidote for chlorine exposure.

The Risks of Chlorine Use in Industry

Chlorine gas is infamous for its lethal effects, posing significant risks to human health. Even minimal exposure can lead to severe respiratory distress, suffocation, and, in extreme cases, death. Even brief exposure to concentrations as low as 2.5 mg per liter can be fatal in minutes.

The dangers of chlorine are not just historical but persist in modern industrial settings. Numerous chlorine-related accidents have resulted in tragic loss of life and long-term environmental damage. Several major incidents serve as stark reminders of the ongoing risks associated with chlorine gas.

• Germany (1915): Chlorine was first used as a chemical weapon during World War I. Its deployment at Ypres marked a grim milestone in modern warfare, showcasing its deadly potential. (Learn More)

• Phoenix, Arizona (1976): On July 20, 1976, a tanker truck carrying chlorine gas overturned on a highway in Phoenix, Arizona, releasing a large cloud of chlorine. Nine people were killed, and more than 100 were injured. This accident was one of the deadliest chemical spills in U.S. history. (CSB/NTSB)

• McCalla, Alabama (1978): In 1978, a chlorine gas release occurred when a railcar derailed in McCalla, Alabama. Chlorine gas spread into the surrounding residential area. Three people died, and dozens were hospitalized due to the chlorine gas exposure. Many nearby residents had to evacuate the area. (NTSB)

• Missoula, Montana (1996): On April 11, 1996, a tanker truck crashed in Missoula, Montana, spilling chlorine gas into the environment. One person was killed, and several others were injured due to chlorine exposure. Emergency responders faced challenges in containing the spill. (NTSB)

• Festus, Missouri (2002): On August 14, 2002, a major chlorine spill occurred at a DPC Enterprises plant in Festus, Missouri. A transfer hose ruptured while chlorine was being moved between rail cars, releasing about 48,000 pounds of chlorine gas into the air. Sixty-three people were hospitalized, with hundreds evacuated from the area. The spill led to breathing problems, eye irritation, and other health effects for those nearby. (CSB)

• Graniteville, South Carolina (2005): On January 6, 2005, a freight train carrying chlorine derailed in Graniteville, South Carolina, releasing chlorine gas into the atmosphere. The accident occurred when a Norfolk Southern train collided with a parked train. Nine people died, including the train engineer, and at least 250 people were injured due to chlorine gas exposure. Thousands were evacuated from the surrounding area. (USDOT)

These accidents highlight the risks associated with chlorine’s storage, handling, and transportation. Its accidental release can pose an immediate hazard to human life and cause lasting environmental damage.

Join Us in Creating a Safer, Cleaner Future

Our commitment to a chlorine-free process is a reflection of our dedication to protecting the environment and everyone impacted by our work. From our founding to today, CASS has never and will never use chlorine. We are proud to set the standard for safe, sustainable, and innovative aluminum production.