Top 10 Most Hazardous Chemical Companies in the United States

The chemical industry in the United States is a cornerstone of modern manufacturing, producing everything from life-saving medicines to important materials used in daily life. The top 50 chemical producers play a major role in supporting key industries like agriculture, construction, and healthcare. However, this same industry that powers progress also harbors a dangerous side. Hazardous processing practices and toxic emissions from these companies pose serious risks to public health and the environment.

As communities grapple with the environmental impact of industrial operations, it becomes clear that balancing innovation with responsibility is essential. Failing to address the hazardous practices of some companies can lead to long-term consequences for air and water quality, as well as the well-being of workers and surrounding populations. Recognizing the importance of holding these companies accountable is the first step toward safeguarding both our environment and public health.

In 2023, incidents involving companies like Dow Corp and BASF have drawn attention to the critical need for improved safety measures in the chemical group sector. The ongoing challenges in the petrochemical and plastic industries highlight the urgency of reform. While this article focuses on American companies, China's largest chemical enterprises are largely unregulated.

The Criteria for Ranking the Most Hazardous Chemical Companies

Determining which companies pose the greatest risks requires a careful look at multiple factors. Companies with the most significant toxic emissions and frequent environmental violations naturally rank high on the list. Additionally, poor worker safety and hazardous material handling further contribute to their harmful impact. The criteria used for ranking include:

• Toxic emissions: Levels of pollutants released into the environment by producers.
• Environmental violations: Documented cases where companies fail to meet legal standards for processing.
• Worker safety: Incidents of unsafe working conditions or exposure to hazardous materials.
• Long-term public health risks: The effects of these companies' operations on local communities.
• Company (or chemical corp) reported incidents or those of a wholly-owned subsidiary.

These factors help identify the most dangerous players in the sector and highlight the ongoing need for stricter oversight in the realm of petrochemical production.

Source : Envato 

The 10 Most Hazardous Manufacturing Companies in the United States

Now, here's our list of the top 10 most hazardous manufacturing concerns in the country. 

1. Kuehne Chemical Company (New York/New Jersey)

Hazard type: Toxic Emissions and Hazardous Material Spills
Location: New York/New Jersey
The population at risk: Over 12 million.
Environmental violations: Documented spills causing air and water contamination.
Health impact: Ongoing legal disputes indicate public health risks.

How to Protect Yourself

• Gas Mask: Filters chlorine.
• Chemical-resistant Suits: Full-body protection.
• Emergency Respirators: For rapid leak response.

Source: MIRA Safety 

Kuehne Chemical Company is regarded as the most hazardous chemical company in the United States. Located in the densely populated New York/New Jersey area, the company is primarily involved in the production of liquid bleach, a vital product used across various industries. Despite its essential role in chemical processing, Kuehne’s operations have placed more than 12 million people at risk due to its toxic emissions and dangerous processes.

Documented environmental violations have revealed the company’s alarming safety track record. The facility has been linked to significant hazardous material spills and inadequate waste disposal methods, which have raised serious concerns among public health officials and environmental groups. A rising amount of legal disputes have further highlighted Kuehne Chemical’s lack of compliance with regulatory standards, as lawsuits over air and water contamination have mounted over the years.

The hazardous practices employed by Kuehne Chemical not only affect the environment but also pose immediate health risks to surrounding communities. As one of the top chemical companies in the U.S., it stands out due to its disproportionate impact on public health and environmental safety. The company’s toxic emissions contribute heavily to air pollution, while ongoing legal violations expose the lack of stringent oversight in its operations.

In 2022, Kuehne faced increasing scrutiny alongside other leading companies like Dow Chemical and BASF. As concerns grow about chemical companies worldwide, the need for stronger regulations becomes more pressing to ensure safety and compliance..

2. KIK SoCal Inc. (Los Angeles, CA)

Hazard type: Chemical Contamination and Toxic Emissions
Location: Los Angeles, CA
The population at risk: Over 4.9 million.
Environmental violations: Documented cases of toxic chemical leaks impacting air and water quality.
Health impact: Ongoing legal disputes highlight significant public health concerns.

How to Protect Yourself

• Gas Mask: Filters harmful chemical vapors.
• Toxin Detectors: Detects contaminants in drinking water and food.

Source: MIRA Safety 

KIK SoCal Inc. has been a prominent player in the chemical sector for years, with a focus on producing household and industrial cleaning chemicals. Based in Los Angeles, this facility operates in a highly populated area, placing more than 4.9 million people at risk. The company’s involvement in hazardous practices has made it one of the leading examples of how chemical contamination can have severe effects on the environment and public health.

KIK SoCal has faced multiple documented cases of environmental contamination, including toxic chemical leaks that have polluted both local water supplies and air quality. These incidents have resulted in widespread health concerns and legal disputes. Despite efforts to comply with regulatory standards, the company has repeatedly found itself entangled in lawsuits due to its poor management of toxic emissions and hazardous waste disposal.

The environmental impact of KIK SoCal’s operations is significant. High levels of pollutants have been traced to nearby ecosystems, damaging wildlife and contributing to long-term ecological damage. The company’s high-risk practices, including insufficient safety protocols and outdated waste treatment systems, continue to exacerbate the risks for both the environment and surrounding communities. These ongoing violations highlight the need for stronger oversight and stricter enforcement of environmental regulations within the chemical vertical-especially with coating.

3. Paulsboro Refining Company (Paulsboro, NJ)

Hazard type: Worker Safety Violations and Toxic Chemical Exposure
Location: Paulsboro, NJ
The population at risk: Around 3 million.
Environmental violations: Breaches of the Clean Air Act leading to fines exceeding $65 million.
Health impact: Persistent safety violations have resulted in fatalities, injuries, and community health risks.

How to Protect Yourself

• Gas Mask: Essential for protection against toxic emissions
• Personal Protective Equipment (PPE): Includes gloves and suits for safe handling of chemicals
• Emergency Response Plans: Critical for workers to understand protocols during chemical spills
  
  

Source: MIRA Safety 

PBF Energy's Paulsboro Refining Company is a major player in the US oil refining industry, producing gasoline, diesel, and jet fuel. The company uses hydrofluoric acid, a highly hazardous chemical, in its refining process, placing around 3 million people at risk. Known for its significant influence in the US chemical sector, the company has faced numerous worker safety violations over the years. These violations have led to multiple legal disputes and penalties, including fines exceeding $65 million for breaches of the Clean Air Act.

The refinery has been criticized for its hazardous conditions, with reports of inadequate safety measures leading to several worker fatalities and injuries. OSHA inspections have revealed persistent safety violations, including improper handling of chemicals and insufficient emergency procedures. These violations have had a lasting community impact, raising concerns about both worker safety and environmental health risks.

The company's operations have not only harmed its employees but have also affected surrounding communities, where toxic emissions and chemical contamination have caused environmental degradation. Despite its significant role in the chemical processing sector, Paulsboro Refining’s legacy of safety issues continues to pose a threat to both workers and residents. Paulsboro Refining remains one of the most dangerous companies to work and one of the most hazardous chemical companies in the world.

4. Torrance Refining Company LLC (Torrance, CA)

Hazard type: Air Pollution Violations
Location: Torrance, CA
The population at risk: Local communities affected by air quality degradation.
Environmental violations: Fines totaling $625,000 in 2021 for harmful emissions, with additional fines of $350,000 in 2020 and $37,500 in 2019.
Health impact: Ongoing air pollution issues raise significant public health concerns in surrounding areas.

How to Protect Yourself

• Air Quality Monitors: Use devices to track local air pollution levels.
• Air Purifying Masks: Effective for filtering harmful airborne particles.
• Air Purifiers: Improve indoor air quality by reducing airborne contaminants.

Source: MIRA Safety 

Torrance Refining Company is a key player in the chemical sector, specializing in the production of refined petroleum products. However, from 2019 to 2021, the company faced multiple fines for air pollution violations issued by the South Coast Air Quality Management District (CA-SCAQMD). The most significant fine, $625,000, was imposed in 2021 due to the company’s failure to control harmful emissions, contributing to degraded air quality and potential health risks in the region.

In 2020, another violation resulted in a $350,000 fine, while a 2019 incident saw the company penalized $37,500. These recurring fines reflect ongoing issues with the company’s environmental compliance, and although water pollution hasn’t been a primary concern, the impact of the company’s air pollution violations on surrounding communities cannot be overlooked.

Additionally, as part of the broader global specialty chemicals market, Torrance Refining Company faces challenges like exchange rate fluctuations and the ongoing economic slowdown affecting various market sectors. The company's financial results indicate that maintaining compliance with environmental regulations is crucial for sustainable solutions in their materials business.

5. Delaware City Refining Company LLC (Delaware City, DE)

Hazard type: Environmental Violations
Location: Delaware City, DE
The population at risk: Local communities affected by air and water quality issues.
Environmental violations: Major fines include a $950,000 settlement in 2019 for Clean Air Act violations and a $218,000 settlement in 2024 for air quality permit violations.
Health impact: Ongoing releases of hazardous chemicals raise significant public health concerns.

How to Protect Yourself

• Water Filtration Systems: Essential for clean drinking water.
• Air Quality Monitors: Track local air pollution levels to stay informed.
• Personal Protective Equipment (PPE): Wear masks and gloves when in areas affected by pollution.

Source: MIRA Safety 

Delaware City Refining Company, a subsidiary of PBF Energy, has a significant influence on the US oil and gas industry, contributing to fuel production across the country. However, its operations have been marred by ongoing environmental violations. Since its restart in 2010, the refinery has faced numerous fines related to air and water quality violations, including a major $950,000 settlement in 2019 for violations of the Clean Air Act. Additionally, the facility has been penalized for fires, pollution, and other hazardous incidents, including a settlement in 2024 that totaled $218,000 to resolve air quality permit violations.

These legal disputes highlight the company's challenges in maintaining compliance with environmental standards. Issues such as the release of hazardous chemicals into nearby ecosystems have raised concerns among regulators and local communities alike. The company continues to be scrutinized for its hazardous practices and their impact on the surrounding area. Despite these challenges, Delaware City Refining remains an important player in the U.S. chemical and oil sectors, but the recurring environmental fines emphasize the need for stricter enforcement of regulations.

Moreover, Delaware City Refining’s practices illustrate the broader concerns within the industry, where the management of hazardous materials often intersects with economic pressures. Companies like DowDuPont, LG Chem, and LyondellBasell nv Industries have faced similar challenges, revealing the complexities of navigating environmental regulations while maintaining operating income. The ongoing scrutiny over their practices not only impacts their profitability but also reflects a growing demand for sustainability in the sector.

As companies based in the U.S. and abroad continue to confront these issues, it is vital to prioritize compliance and implement best practices for hazardous waste management. The regulatory environment demands that companies innovate in their approaches to supply chain management, ensuring safety and sustainability throughout their operations. Moving forward, the focus on developing polyolefin and other specialized materials should align with stricter regulations, driving a more responsible and eco-friendly industry.

6. Martinez Refining Company LLC (Martinez, CA)

Hazard type: Hazardous Waste Management Violations
Location: Martinez, CA
The population at risk: Nearby communities exposed to hazardous waste.
Environmental violations: Penalized $94,970 in December 2023 for improper hazardous waste disposal.
Health impact: Increased risk of exposure to toxic chemicals affecting public health.

How to Protect Yourself

• Water Filtration Systems: Needed for removing contaminants from drinking water.
• Detection Paper: Determine the presence of hazardous substances in residential areas.
• Personal Protective Equipment (PPE): Use masks and gloves when in potentially contaminated environments.

Martinez Refining Company, a key subsidiary of PBF Energy, is deeply embedded in the oil and gas industry, refining crude oil into essential fuels and products, some of which are used in personal care items. Despite its critical role, the company has repeatedly failed to comply with environmental regulations, particularly in the area of hazardous waste management. In December 2023, Martinez Refining was penalized $94,970 by the California Department of Toxic Substances Control for violating hazardous waste disposal rules. This fine added to the company's costs in the fiscal year, highlighting the financial risks of non-compliance.

Following the penalty, the company reported that it is taking steps to improve its hazardous waste management practices. These violations highlight a broader issue with how the company handles toxic byproducts of its refining processes, leading to long-term consequences. Improper hazardous waste disposal doesn’t just affect the immediate surroundings—it can seep into groundwater, contaminate soil, and disrupt local ecosystems, leaving behind significant long-term environmental damage. These practices also pose serious risks to public health, as communities near the refinery may face increased exposure to dangerous chemicals.

The company's environmental track record illustrates the need for stronger oversight and better compliance measures within the chemical makers sector. Martinez Refining’s continued environmental effects raise concerns about the sustainability of its operations, as poorly managed hazardous waste threatens to undermine both local and regional environmental stability. Additionally, the top 100 chemical companies worldwide by revenue are facing increasing scrutiny over their waste management practices, reflecting a growing awareness of the need for sustainability across the industry. As leading companies like Celanese, Bayer, Sherwin-Williams and BASF SE adapt to changing regulations, the importance of robust waste management systems becomes clearer, particularly in light of the global challenges related to specialty materials and resin production.

7. DuPont (Wilmington, DE)

Hazard type: Persistent Organic Pollutants (POPs)
Location: Wilmington, DE
The population at risk: Thousands affected by contaminated drinking water.
Environmental violations: Multi-billion-dollar settlement in 2023 for PFAS-related lawsuits.
Health impact: Ongoing health risks from exposure to PFOA and related chemicals.

How to Protect Yourself

• Water Filtration Systems: Effective for removing PFAS and other contaminants from drinking water.
• Home Testing Kits: Use to check for hazardous substances in water supplies.
• Protective Gear: Wear gloves and masks when handling products containing known harmful chemicals.
  
  

DuPont has been a central figure in the chemical companies sector for decades, but its legacy includes significant involvement with persistent organic pollutants (POPs) like perfluorooctanoic acid (PFOA), a key component in the production of Teflon. Despite assurances to phase out PFOA, DuPont faced continued scrutiny for ongoing discharges of these chemicals, which have contaminated drinking water supplies and affected thousands of people in regions surrounding their production facilities. 

In 2023, DuPont, along with its spin-off Chemours, agreed to a multi-billion-dollar settlement to resolve lawsuits over PFAS (per- and polyfluoroalkyl substances), a class of POPs, as they continued to face legal challenges regarding their failure to manage the long-term environmental impact of these chemicals.

DuPont's regulatory issues underscore the difficulties in addressing the lasting effects of POPs, as even after the cessation of their use, their persistence in the environment requires ongoing remediation efforts. The company has been involved in extensive legal disputes and settlements related to contamination and regulatory challenges, particularly around water contamination. This case highlights the broader implications for chemical companies managing hazardous materials and the need for stricter regulations to mitigate long-term damage from POPs.

8. Honeywell (Geismar, LA)

Hazard type: Toxic Chemical Leaks
Location: Geismar, LA
The population at risk: Nearby residents affected by chemical releases.
Environmental violations: Multiple leaks, including a significant explosion in January 2023 releasing hydrogen fluoride and chlorine.
Health impact: Ongoing public health risks due to repeated incidents and hazardous practices.

How to Protect Yourself

• Gas Masks: Used for filtering out toxic gasses like hydrogen fluoride and chlorine.
• Emergency Response Plans: Know the protocols for chemical leaks in your area.
• Air Quality Monitors: Use devices to track local air pollution levels to stay informed.

Honeywell's Carville facility in Louisiana has a troubling history of toxic chemical leaks, with one of the most serious incidents occurring in January 2023. An explosion released hydrogen fluoride and chlorine, two highly hazardous chemicals, prompting a shelter-in-place order for nearby residents and road closures. This incident followed multiple previous leaks, including one in July 2022, and a fatal accident in the previous year. 

Over the past three years, the facility has reported 11 accidental releases of toxic chemicals. Honeywell’s facility produces hydrofluoric acid, fluorocarbon refrigerants, and other chemicals, raising concerns about ongoing public health risks and the facility’s hazardous processes. These repeated incidents have underscored the need for stricter safety protocols within the chemical industry.

9. Dow Chemical Company (Plaquemine, LA)

Hazard type: Clean Air Act Violations
Location: Plaquemine, LA
The population at risk: Residents near the facility.
Environmental violations: Multiple violations, including six explosions in July 2023 that released ethylene oxide.
Health impact: Ethylene oxide exposure poses long-term health risks, including cancer and respiratory issues.

How to Protect Yourself

• Gas Masks: Best for filtering out toxic fumes from chemical releases.
• Emergency Shelters: Know your local shelter-in-place procedures in case of chemical incidents.
• Air Quality Monitors: Keep track of local air quality to stay informed about hazardous conditions.

Dow Chemical's facility in Plaquemine, Louisiana, has been at the center of multiple Clean Air Act violations, with the most recent incident occurring in July 2023. Six explosions shook the plant, triggering fires and releasing dangerous chemicals, including ethylene oxide, a highly toxic and flammable substance. Residents were ordered to shelter in place, and authorities closed nearby roads to prevent further exposure. This is one of many serious incidents at the facility, reflecting ongoing challenges in controlling emissions and securing compliance with air quality standards.

Although no injuries were reported during this event, Dow Chemical has a history of environmental violations tied to its handling of toxic chemicals. Ethylene oxide, which has been linked to cancer and respiratory issues, poses long-term health risks to surrounding communities. The company’s employee safety practices have faced scrutiny, and the company is under increasing pressure from regulatory bodies to improve its safety standards. As one of the leading chemical producers in America and a participant in the chemical industry, ongoing violations continue to threaten public health and the environment.

10. Norfolk Southern Railway (East Palestine, OH)

Hazard type: Hazardous Material Transportation Failure
Location: East Palestine, OH
The population at risk: Residents and workers involved in the cleanup.
Environmental violations: A train derailment in February 2023 released hazardous chemicals, including vinyl chloride.
Health impact: Immediate evacuations and shelter-in-place orders due to toxic exposure risks.

How to Protect Yourself

• Emergency Preparedness Kits: Best for families living near railways transporting hazardous materials.
• Gas Masks: Provide protection against toxic chemical fumes.
• Water Filtration Systems: Important for safe drinking water in case of contamination.

In February 2023, a train operated by Norfolk Southern Railway derailed in East Palestine, Ohio, causing several cars carrying hazardous chemicals, including vinyl chloride, to spill and catch fire. This incident led to the release of toxic chemicals into the air and groundwater, prompting immediate evacuations and shelter-in-place orders for nearby residents. The hazardous material transportation failure also exposed workers handling the cleanup to serious health risks, including potential long-term effects from chemical exposure.

The company’s handling of hazardous materials raised significant concerns about the safety of transportation processes in the chemical industry. The incident underscored the need for stricter regulations on hazardous material transport, as well as better protections for workers who are frequently exposed to dangerous chemicals during transport accidents.

Norfolk Southern faced criticism for failing to adequately safeguard both its employees and the local community from exposure to hazardous chemicals during and after the derailment, highlighting the risks inherent in transporting such materials across populated areas. The financial impact of such incidents can affect the operating income of leading chemical makers involved in hazardous materials transport, as they must manage the complexities of compliance with safety regulations and deal with potential fines.

Moreover, the incident raises questions about companies based in high-risk areas and their commitment to sustainability. The scrutiny on DowDuPont and other top chemical makers reinforces the importance of maintaining high standards of safety and transparency in operations. With rising concerns about the global chemical market, it is crucial for these companies to prioritize R&D efforts aimed at improving safety protocols and reducing hazardous material exposure risks.

The Importance of Regulatory Oversight for Chemical Companies

The cases discussed highlight the significant risks posed by hazardous chemical enterprises, from toxic chemical leaks to improper waste disposal and worker safety violations. These incidents underline the need for stronger regulatory oversight so that companies based in the chemical industry prioritize safety and environmental protection. Without stricter regulations and more consistent enforcement, the dangers associated with hazardous materials will continue to threaten public health and the environment.

Previously, companies like Dow Chemical and DuPont exemplified these challenges, often listed in the top 50 chemical companies, showcasing the need for enhanced sustainability. The company’s financial results often reflect the profitability of these leading chemical companies in the context of ongoing geographical and global chemical market pressures, including exchange rates and GDP growth factors affecting their operations.

To mitigate these risks, comprehensive safety protocols, better monitoring of hazardous substances, and improved handling of toxic chemicals must be mandated across the industry. Stronger regulatory measures will not only protect communities but also create a safer working environment for employees who are regularly exposed to dangerous chemicals. Ultimately, enforcing these changes guarantees the long-term safety and sustainability of chemical manufacturing operations, aligning with the goals set forth by the American Chemical Society and other regulatory bodies.

These efforts also reflect the world's top chemical makers need to address issues of specialty materials and adhesive products, particularly as they manage market segments like consumer goods and textile industries. As these top companies strive to meet double-digit growth targets in the fourth quarter, their commitment to compliance and safety becomes even more critical. Protect yourself from hazardous environments with top-quality safety gear…visit MIRA Safety today!