Fatal Toxic Gas Exposure During Tank Cleaning at Ethanol Plant
Apr 27, 2026
Basic Incident Information
Date of incident: Tuesday, 28 April 2026 (reported 28 April 2026)
Location: Ethanol plant at Thervoy Kandigai, near Gummidipoondi, Tiruvallur district, Tamil Nadu, India
Incident type: Toxic gas exposure and confined‑space–type incident during tank cleaning
Workers involved: 5 migrant workers
Incident Description
The incident occurred at an ethanol factory in Thervoy Kandigai, where a group of migrant workers were assigned to clean a water tank. During the work, toxic gas accumulated in or around the tank, and a worker from Odisha, identified as Dhananjay Mali, was overcome by fumes and fell into the tank.
Four co‑workers attempted to rescue him but also inhaled the toxic gas and lost consciousness. Fire and rescue personnel responded to the scene and retrieved all five workers using appropriate safety equipment.
Dhananjay Mali was declared dead at the scene, while the four rescued co‑workers were transported to Tiruvallur Government Hospital, where they remain in critical condition.
Casualties
Fatalities: 1 worker (Dhananjay Mali, from Odisha) died at the scene.
Injuries: 4 co‑workers unconscious due to toxic gas inhalation, all in critical condition at Tiruvallur Government Hospital.
Emergency Response
Tamil Nadu Fire and Rescue Services personnel attended, entered the hazardous area with safety equipment, and recovered all five workers.
Medical teams at Tiruvallur Government Hospital are treating the four surviving workers; no further medical details are provided in the report.
Preliminary Learnings and Safety Focus
Although the article does not specify the exact gas involved or the detailed procedure, the scenario clearly reflects a confined‑space/toxic‑atmosphere hazard:
Any work involving entry into tanks, pits, or similar confined spaces at ethanol or chemical plants must follow a formal confined‑space entry permit system, including atmospheric testing (oxygen, flammable, toxic) before and during entry, mechanical ventilation, and standby attendants.
Rescue attempts by unprotected co‑workers are a recurrent cause of multiple casualties; emergency planning must emphasise “do not enter without protection” and ensure availability of trained rescue teams and appropriate respiratory protection.
Worker training, particularly for migrant workers, must cover the invisible nature of many toxic gases, symptoms of exposure, and the need to stop work and evacuate if unusual odours or discomfort occur.
Employers should ensure that tank‑cleaning tasks are risk‑assessed, with engineering controls, equipment, and supervision proportionate to the potential for toxic vapour accumulation.
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