1997 Shell MDS Explosion In Bintulu: Former Fire Chief Recalls One Of Malaysia's Toughest Industrial Fire Operations

By Zaphne Philip

KUCHING, June 30 (Bernama) -- What was meant to be a joyful Christmas Eve turned into a night of panic when a powerful explosion rocked the Tanjung Kidurong industrial area in Bintulu on Dec 25, 1997.

The blast originated from the Shell Middle Distillate Synthesis (Shell MDS) plant, the world’s first commercial gas-to-liquids (GTL) conversion facility, which had begun operations in 1993.

Recalling the incident, former Malaysian Fire and Rescue Department (JBPM) Fire Safety and Prevention Division director Datuk Khirudin Drahman described it as one of the most challenging operations ever faced by firefighters, given the scale of the industrial blaze and the limited preparedness at the time.

“At that time, I was serving as the Sibu Fire and Rescue Station (BBP) chief. The department’s readiness level and available equipment to handle an industrial emergency of that magnitude were still limited.

“As soon as the emergency call was received, additional personnel and assets were immediately mobilised from Sibu to Bintulu that same night because local resources alone were insufficient,” he told Bernama.

Khirudin said the journey from Sibu to Bintulu then took about two and a half hours, and members departed immediately without time to collect personal belongings.

“Upon arriving, we were stunned by the extent of the damage. Fortunately, no fatalities were recorded, and only several workers suffered minor injuries, but firefighting operations continued for an entire week.

“We worked around the clock preparing and deploying all available equipment. Initially, we believed existing resources would be adequate, but once on site, we realised they were far from enough,” he said.

According to Khirudin, the explosion was triggered by damage to the air separation unit, causing a major blast that ignited two of the plant’s 12 storage tanks.

Although the facility was located within a buffer zone away from residential areas, he said the incident still posed risks to the surrounding public due to the hazardous nature of the fire, which required specialised suppression agents.

Khirudin said his earlier participation in a Hazardous Materials (HAZMAT) course in Sweden in 1994 helped him recognise that industrial fires of this scale required specialised firefighting foam, which was unavailable in Bintulu at the time.

“The supplies had to be transported from Seremban, Labuan and Kuala Lumpur before being shipped to Bintulu. It took nearly four days before all the required equipment arrived. It was an experience that truly tested physical and mental endurance,” he said.

Following the incident, the plant was fully shut down to facilitate investigations, clean-up and reconstruction efforts, which took nearly three years to complete.

Operations resumed in 2000 with a significantly enhanced safety system design.

Khirudin noted that as Sarawak continues to strengthen its position as a major gas supply hub in Asia, more comprehensive risk assessments, emergency response protocols, and prevention and protection measures have since been implemented.

“Despite the risks involved, the energy and gas sector continues to offer significant returns that support industrial growth and national economic development,” he said.

He added that the incident marked a major turning point for JBPM in strengthening its industrial firefighting and hazardous materials response capabilities through improved assets, training and specialised HAZMAT expertise.

-- BERNAMA