Sulfuric Acid Leak at BWC Near Channelview Releases 1M Gallons into Houston Ship Channel

In the early morning hours of December 27, 2025, a catastrophic industrial accident at a chemical facility near Channelview resulted in approximately one million gallons of sulfuric acid spilling into the Houston Ship Channel. The incident, which began around 1:40 a.m., sent two people to the hospital and required medical evaluation of more than 40 others.

What Happened at the BWC Channelview Facility

According to the Harris County Sheriff's Office, the incident occurred at the BWC Corporation facility located on Jacintoport Boulevard near Channelview, Texas. Initial reports suggested an explosion, but authorities quickly determined the actual cause: a catwalk structure had collapsed onto a 6-inch sulfuric acid supply line, rupturing the pipe and causing the massive chemical release.

The Channelview Fire Department, which led the hazardous materials response, dispatched crews to the scene along with Harris County hazmat teams, fire marshals, and multiple federal and state agencies, including the U.S. Environmental Protection Agency and U.S. Coast Guard.

The Harris County Sheriff's Office confirmed that two individuals were transported to local hospitals suffering from respiratory issues. An additional 40 people from two ships docked at the San Jacinto Port underwent medical evaluation at a triage site established at the scene.

Harris County Fire Marshal's Office personnel monitored air quality throughout the incident after receiving several reports of people feeling sick and experiencing breathing difficulties. Local workers reported being able to smell the chemical release in the air during the early morning hours.

Environmental Impact & Public Safety Measures

Authorities estimate that approximately one million gallons of sulfuric acid entered the Houston Ship Channel. The Texas Commission on Environmental Quality responded to the scene to assess environmental impacts and monitor the situation, and officials are continuing to monitor potential impacts to aquatic life in the ship channel.

Because the leak occurred far enough from residential areas, there were no evacuation or shelter-in-place orders issued. However, authorities established a security perimeter to protect nearby businesses and plant operations. Deputies managed traffic control around Sheldon Road and Jacintoport Boulevard while emergency response efforts continued.

Response & Containment Efforts

Emergency responders worked quickly to contain the sulfuric acid leak. According to the Harris County Sheriff's Office, the leak was stopped shortly after 6:00 a.m. Cleanup operations continued throughout the morning and into the afternoon.

Despite the severity of the spill, the Houston Ship Channel remained open to vessel traffic throughout the incident, though some nearby roads were temporarily closed to facilitate emergency vehicle access.

What Is Sulfuric Acid & Why Is It Dangerous?

Sulfuric acid is one of the most widely used industrial chemicals in the United States, commonly employed in petroleum refining, chemical manufacturing, and fertilizer production. The corrosive chemical poses serious health risks, particularly through inhalation of vapors or mists.

Exposure to sulfuric acid can result in:

• Respiratory distress and difficulty breathing
• Severe burns to skin and eyes upon contact
• Throat and nasal passage irritation
• In severe cases, chemical pneumonitis and pulmonary edema

The large-scale release of this hazardous material into the environment also raises concerns about water quality, aquatic ecosystem impacts, and potential long-term environmental contamination.

Chemical Facility Safety & Regulatory Oversight

This incident at the BWC facility raises important questions about industrial safety in the Houston area. The region's concentration of petrochemical and industrial facilities makes workplace safety and accident prevention non-negotiable to protect workers and surrounding communities alike.

Federal and state regulations require chemical facilities to maintain rigorous safety standards, conduct regular equipment inspections, and implement comprehensive emergency response plans. An investigation into the catwalk collapse and sulfuric acid leak will determine its cause and whether proper maintenance and safety measures were taken.

Our thoughts are with everyone affected by this incident: the workers, their families, and the emergency responders who worked tirelessly to contain the spill and protect the community.