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Explosion in a Methanol Synthesis Unit (770)

The accident happened in a low pressure methanol plant, commissioned in summer 1971 . A 6 in. pipe, below the methanol synthesis gas compressor inter-stage relief valve, failed releasing hydrogen-rich synthesis gas into the methanol area. The pipe failed at the pipe-flange junction. Syngas was ignited by an unknown ignition source and the resultant fire burned 10-20 minutes above the synthesis gas compressor. No damages to personnel are reported, even though windows were broken within a distance of 270 m, due to the explosion.

Explosion in a Fertilizers Plant (223)

The vent occurred in the ammonia production unit. A minor leak had been detected in a flange on the piping of the ammonia synthesis loop (operating at 250 bar). The company called a specialized external contractor to perform an on-stream repair of the valve. This solution was chosen because of for the limited extents of the leakage and the economic costs and efforts associated to a shut-down of a very complex system.

Explosion at a Nuclear Power Plant (124)

The event occurred in the steam condensing line of the residual heat removal system the nuclear reactor. Radiolysis generated hydrogen and oxygen which then accumulated in high concentration in the pipe. During the periodical manual start-up test of the High Pressure Coolant Injection (HPCI) system, a pressure spike due to pressure fluctuations in the pipe led to ignition followed by detonation. The pipe burst open and pieces were projected damaging the surrounding structure.

Explosion in a Calcium Plant Due to Unwanted Hydrogen Production (123)

The incident took place in a calcium powdered wire manufactory of "Chepetsk Mechanical Plant". Some amount of water find it's way in a container where the mixing of different powders took place. As a result of chemical reaction active evolution of hydrogen occurs which results in accidental explosion from a spark. The explosion caused 5 injuries and 4 fatalities.

Syngas Fire in in a Chemical Plant (91)

The event occurred while re-starting the ammonia production unit after a technical stop, a synthesis gas (50% hydrogen, 17% ammonia, methane and nitrogen) leak ignited on a flange located just after the synthesis reactor. Emergency shutdown of the unit was executed and the fire was extinguished in a bit less than 1 hour. The leaking at the flange was caused by a tightening torques of the bolt which were not adapted to the exceptional conditions prevailing during the accident.
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