After the accident, the Medical group at work asked me to write down what happened so they could include that as part of the accident report. The only thing I didn't include was that I was trying to get this all done as fast as I could because I had to pee, and I was going to stop on my way out to the shop floor. :) Anyway, I reread it today, hoping that maybe the further I get from it and the more I know I'm safe now, maybe it won't scare me so much. Since I have this blog forum, I'm copying it in for you all to read. When I look at Emily and think about the what a wonderful little family we are, I am certain that she is the reason that glass hit my shoulder instead of my neck. What a shame to deny this wonderful little being of her existence on account of my own stupidity.
July 19, 2006:
"My original plan for the afternoon was to use ethanol to clean off the hardness testers out in Dept.38 and 39, hoping to improve their hardness results. I wanted a full bottle of ethanol in the little spray bottle, so I refilled it from the glass jug under the hood cabinet. This was almost empty so I went to the flammables cabinet and started to fill it, when I realized I had grabbed the acetone instead by accident. I immediately took this into the hood and dumped it down the drain, flushed with lots of water. Then I left the ethanol jug on the counter, upsidedown over a paper towel, to dry, thinking it might be a bad idea to add ethanol to a wet jar.
"Then I saw that the etch jar was almost empty too, and I thought as long as I had my acid gloves on and was working with pouring ethanol, I would fill it up too. But, the ethanol jug was still drying and I thought I’d do the acid first and the ethanol second so I’d only have to get it out once, for the acid and for the ethanol at the same time. (This is the first time I should’ve realized to do the ethanol first for safety).
"Each jug holds 2.5 L. The acid jug is a 10% nitric acid with 90% ethanol. I estimated that I should make 2L of solution because there was a little (an inch or so) still left in the jug. This would mean 200 mL of acid and 1800 mL of ethanol. I took the nitric acid from the acids cabinet in the outer lab into the hood, and measured out 200mL and put it in the 10% jug. I did all this under the hood, thinking it would be safer to pour acid in there, but this is the second point where I should’ve realized that the ethanol should go in first. Then I put the lid on the 10% jug and the nitric acid, and went out in to the outer lab. I put the nitric acid jug away in the acids cabinet, and took the other jug over to the flammables cabinet, where the ethanol is.
"I knew that 10% nitol reacts with ethanol at that concentration, because if a small plastic spray bottle is filled fairly full and tightly screwed shut, the pressure inside will build up (especially if shaken) and it’ll spew out the nozzle. This is yet another reason for me to know not to put large amounts of acid with small amounts of ethanol, but I wasn’t really thinking about the small amount already in the jar. The funnel I used was also the same funnel I had used to pour the acetone, so I had rinsed it off really good after that mishap. I hadn’t dried it, though, and I noticed the acid reacted a bit with the water. This could’ve sped up the reaction in the bottle, but it should’ve been another reason for me to leave the bottle under the hood.
"When I brought the nitol bottle over to the flammables cabinet, I set it up on the filing cabinet, and noticed it was starting to react inside – starting to turn a chemical yellow color, about like the 10% solution does. Thinking it needed venting (like described above), I unscrewed the cap a little. I really thought that would allow some of the venting to escape, but I hadn’t really realized just how much acid I had put in the jar. Then I turned back down to the large canister of ethanol on the floor. I was about 4 feet away for this. I heard the jar hissing a bit, and I looked up and the chemical yellow was turning a rusty brown color with ominous yellow swirls coming up. I looked at it for a second, and actually got pretty scared as the hissing increased and I wondered if I had time to take the cap off. I started thinking it might release a lot of gas from that reaction and would that be dangerous?? I started to reach out with my left hand and took maybe a step towards it, but by then it really was sounding scary, so I started to turn away to my right. All this happened in about 5 seconds, probably. When the jar exploded, I had my left hand extended forward, my face turned down to my right, and my right arm up to start to shield my face. I had my safety glasses and metatarsals on, but not my earplugs or my lab coat.
"The actual explosion sounded like a huge potato gun, a big, deep bang. I didn’t even think about the glass, just was worried that there was acid on me. I have worked with dilute nitric before and been not concerned to get in on me if I washed it off right away, so that was my plan. I went to rinse off my hands and face in the sink under the hood, and I noticed that there were holes in my shirt, at which point I was afraid that the acid was eating through my shirt, and I had to use the shower. I really hated to because I knew it meant that this was really bad, but that’s what it’s for, so I’d better. I noticed a cut on my left ring finger and immediately pulled off my rings on both hands in case it swelled up. Then I was really not wanting to stand in the shower because my finger was bleeding but I figured a little blood on the floor was worth preventing acid burns. I washed off mostly my left side, and then noticed a lot of blood coming off my right side too, where my wrist had a deep cut on it. That’s when I called Kathy. I didn’t know how to stop the shower so I went back to the hood to try to keep the blood a little contained, but I couldn’t because I kept finding more cuts. That’s where Kathy and the medical team found me."
See? it's pretty scary. After they took me to Medical, one of the nurses at the plant that was doing first aid said "Ohhh, I can see collarbone!" which was when I really started to wig out and cry. Up until then, I was just confused, and dazed. But from that point on, I was crying and so very, very scared. Then, the ambulance got lost on the way to the hospital because it couldn't get over I-235 because of the construction, which was frustrating because - remember - I still had to pee!! Then they gave me IV fluids because of the blood loss, too, at which point I tried to realize some humor of the situation so I could stop being so scared. But, it was just awful. I am so glad I had a wonderful boss like Kathy to call, and that my husband and brother and sister-in-law were so fast in getting to the hospital to be with me. And really, it had a happy ending, for what could have happened. I know all this, and I keep hoping that having that perspective and getting some distance (both time and location) from the event would help. But it's still very vivid to me.