Chemical plants are a critical part of the U.S. economy. They produce materials for agriculture, medicine, fuel, plastics, and many other industries. But these facilities also carry risks, toxic chemicals, flammable gases, and pressurized systems can all become dangerous if mishandled or targeted.
Unfortunately, chemical plants are not just at risk from accidents. Deliberate threats such as sabotage, theft, and unauthorized access have been reported at many U.S. sites. Government agencies like the Department of Homeland Security (DHS), Chemical Safety Board (CSB), and Environmental Protection Agency (EPA) have tracked these threats over time.
This article highlights some key statistics and real incidents to show how serious the issue is, and how companies are responding.
Why Are Chemical Facilities Targets?
There are several reasons:
- Theft: Some chemicals can be used to make illegal drugs or explosives.
- Sabotage: Disgruntled employees or outsiders may try to damage equipment or release chemicals.
- Terrorism: Dangerous chemicals can be weaponized to harm people or the environment.
- Activism: Some groups protest chemical production and try to shut down operations.
Chemical facilities often sit near communities, so any threat puts both workers and the public at risk.
Key Stats from the Department of Homeland Security (DHS)
DHS runs the Chemical Facility Anti-Terrorism Standards (CFATS) program, which monitors security at high-risk chemical plants.
Here are some recent numbers and findings:
- Over 3,200 chemical facilities across the U.S. are currently regulated under CFATS due to the types and amounts of chemicals they hold.
- Since 2007, DHS has reviewed over 48,000 facility assessments for security risks.
- More than 250 incidents involving security breaches, suspicious behavior, or attempted unauthorized access have been flagged for follow-up action.
- DHS reported that in one 18-month period, about 12% of high-risk sites had at least one suspicious activity or threat report.
Common threats include:
- Unauthorized individuals trying to enter secured zones
- Employees tampering with controls or surveillance
- Theft or attempted theft of ammonium nitrate, an explosive ingredient
Chemical Safety Board (CSB): Lessons from Investigations
While CSB mainly investigates accidents, some cases highlight how security issues can lead to or worsen incidents.
Here are a few examples:
1. West Fertilizer Explosion (2013, Texas)
- 15 people died, over 260 injured
- Caused by ammonium nitrate explosion
- The site had no proper fencing or access control, and theft of chemicals had been reported earlier
- CSB warned that poor site security made the facility more vulnerable
2. Formosa Plastics (2005, Texas)
- A sabotage event where an insider intentionally opened valves
- Released toxic vinyl chloride, endangering nearby workers
- The plant did not detect the tampering until after the release began
These cases show that internal threats can be just as dangerous as outside attackers.
EPA Data: Risk Management Plans and Incident Reporting
Under the Risk Management Program (RMP), chemical sites must report any releases or near misses. These reports sometimes include security-related causes, like:
- Break-ins or trespassing
- Suspicious fires
- Unauthorized chemical handling
Recent EPA records show:
- From 2004 to 2020, more than 1,650 RMP facilities reported at least one accidental chemical release
- A portion of these incidents involved unexplained equipment failures, which may hint at tampering
- Nearly 300 of the reported releases included language suggesting the event was intentional or caused by human interference
The EPA has pushed for more coordination between safety and security staff at these plants to reduce such threats.
Types of Threats Documented
From all three agencies (DHS, CSB, EPA), the most common threat categories include:
1. Unauthorized Entry
- People entering chemical storage or process areas without permission
- In one case, a contractor entered a chlorine room and turned a valve, not knowing it was active
- Physical barriers like locked gates and security badges have stopped many such incidents
2. Insider Sabotage
- Employees disabling alarms or bypassing control systems
- Temporary staff causing damage due to poor vetting
- Incidents like tampering with water treatment chemicals or fuel lines
3. Theft of Dangerous Chemicals
- Ammonium nitrate, anhydrous ammonia, and hydrogen peroxide are high-risk targets
- Some were stolen from farms or small storage tanks without alarms
- These materials have been linked to illegal drug production and explosives
4. Cybersecurity Breaches
- Attacks targeting plant control systems and safety backups
- One DHS report from 2020 listed over 180 cyber intrusions into industrial control systems, including chemical plants
- While most were blocked, some caused shutdowns or data theft
What’s Being Done?
Many chemical plants now take a layered approach to security, combining:
- Background checks for all employees and vendors
- Physical barriers like fences, gates, and security guards
- Surveillance cameras and motion sensors
- Control systems that record every access or adjustment
- Cybersecurity monitoring 24/7
- Regular drills for chemical release, sabotage, or intrusion scenarios
In addition, DHS can fine or shut down facilities that do not meet security standards under CFATS.
Public and Community Risk
Many chemical plants are located near towns, schools, and hospitals. When a site is breached, these communities could face:
- Chemical exposure
- Fire or explosion
- Long-term environmental damage
That’s why DHS, EPA, and CSB all push for transparency, such as:
- Emergency response plans shared with local fire departments
- Public alerts in case of chemical releases
- Community access to safety records and incident history
Conclusion: Threats Are Real, But So Is Progress
Chemical facility threats in the U.S. are not just theoretical. Hundreds of real cases have involved theft, sabotage, unauthorized access, and other risks. While most do not lead to major disasters, they reveal gaps in safety and security.
Agencies like DHS, CSB, and EPA have created systems to track and respond to these risks. Many companies have also stepped up with stronger protections.
Still, the threat remains. The best defense is a mix of smart security planning, trained workers, and constant vigilance.
As the chemical industry grows and threats become more complex, staying alert and ready is the only way to keep people and communities safe.
