Explosion at a Acetylene Hydrogenation Process
The event occurred at an ethylene production plant. The plant was shutdown at the time as the supply of compressed air to the gauges had inadvertently been switched off. This failure of the air supply was not immediately recognised because of the low pressure alarm was installed before the isolation valve. Shortly after the plant was restarted an unusually high temperature was observed in an acetylene hydrogenation column. Probably the hydrogen supply had not been turned off completely during the shutdown due to a leaking isolation valve and the continued passage of hydrogen through the column led to a gradual increase in temperature. The column thermometers were all located on the outside of the column and registered 120 degrees C when the interior temperature was probably about 400 degrees C. As the plant operator was unaware of this situation, he attempted to reduce the column temperature by passing in additional ethylene. At this high temperature the ethylene was hydrogenated to ethane and the column temperature rose further to about 950 degrees C as the hydrogenation reactions are exothermic. Also the ethylene decomposed into methane, carbon and hydrogen. The hydrogen supply was turned off and the temperature fell to 700 degrees C. The high temperature and pressure generated by the above reactions caused a leakage of flammable gases at a valve flange on a pipe close to the column. An explosion and fire followed.
Event Date
July 7, 1973
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Cause Comments
The immediate cause of the incident was i) the restart of the acetylene hydrogenation reactor after the emergency shutdown, ii) ethylene hydrogenation produced excessive heat.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
ethylene production, acetylene hydrogenation, air compressor, acetylene reactor
Location Type
Location description
Industrial Area
Lessons Learned
Lessons Learned
The series of event which brought to the run-away hydrogenation reaction showed the cricual role of the facility management and of the proper training of personnel. According to the source (see references), The following measures were taken: 1. alarm systems were installed,2. Vessels containing liquefied gas were redesigned to allow for a more rapid depressurisation and discharge,3. Pipes were labelled and made more easy to be distinguished from each other,4. Sprinkler systems were improved and made more effective,5. Personnel was properly trained,6. Operation standards reviewed and improved.
Event Nature
Emergency Action
Firefighters took over 5 hours to achieve a measure of control but the fire continued to burn for a further 80 hours because there was no way of preventing 500 tonnes of hydrocarbons leaking out of the plant and feeding the fire.
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References
H.Koseki et al., Explosion of Acetylene Hydrogentation Section in Ethylene Plant, Failure Knowledge Database, - 100 selected cases
https://www.shippai.org/fkd/en/hfen/HC1000040.pdf
(accessed May 2023)
Same source, available as template at
https://www.shippai.org/fkd/en/cfen/CC1000040.html
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