Explosion in an Ammonia Plant
A mechanical failure occurred in a gasification reactor, which caused a violent (abrupt, sudden) depressurization of the reactor. The consequences were the projection of tiles of the refractory lining (inner coating), and the release of feed (raw, initial) substances and partly transformed substances and reaction products through the top of the reactor. Release of gas through the flange joint of the burner (firebox) of the reactor, caused the rupture of the fastening bolts.Simultaneously (at the same time) a very loud (violent) noise was heard accompanied by (coupled with) the emission of very high flames.
Event Date
December 21, 1997
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Causes
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
gasification reactor
Storage/Process Medium
Location Type
Location description
Industrial Area
Operational Condition
Pre-event Summary
In the ammonia production plant a mechanical failure occurred in the gasification reactor D201 A unit no. 200 which caused a violent (abrupt, sudden) depressurization in the reactor.
Consequences
Number of Injured Persons
5
Lessons Learned
Lessons Learned
- 1. Set up of a daily control routine of the explosibility in the reactor head of both reactors. - 2. installation of a system for the detection of leaks at the flanges of the reactors, through temperature measurement in the flanges, with an alarm system and a register (regulation device). - 3. Setting of the release value (set point) of the temperature (thermal) alarm of the cooling water of the reactor head (exit) at 5C higher than normal operation temperature (45C). Before this change it was set at 70C, after the change it has been set at 50C. - 4. Replacement of the bolts in both reactors according to (in conformance to) the specifications of the project. - 5. Prohibition of any tightening operation of the bolts in case of leakage in the flanges of the reactor during stable (normal) process (production) conditions. The reactor must be shut-down immediately in case of leakage. - 6. Process maintenance of the burner (combustion chamber), usually an inspection is foreseen every 3000 hrs (hours) of operation and always after scheduled and/or not scheduled shut-downs, allowing to clean the lance and of the burner (combustion chamber). - 7. Explosibility measurements every single hour in the reactor heads the first 12 h. (twelve hours) after start-up of the reactors. - 8. Control (audit) of the storage conditions of the joints - 9. Set up of a remote temperature monitoring (control) system at each of the 32 probe points of the reactor, controlled remotely from the control room. - 10. Setting of the of the alarm value (threshold) in the 32 points of the reactor dome at 240C, instead of the previous 300C. - 11. Connection of this alarm (system) to the data-logger - 12. Set up of a verification (control) procedure of all temperature detection (measurement) points located externally to the reactor, including tests (check-up procedures) during the start-up process of the reactor.
Event Nature
Emergency Action
Unknown
Release Type
Ignition Source
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References
From public part of MARS database