Explosion and Fire in Chemical Plant During aluminum Alkyl Cleaning Process
Explosion, with consequent fire, in chemicals production plantThe accident occurred in the organo-metallic compound production unit, on a transport container for aluminum alkyls, which exploded during a cleansing process at the washing station. The incident was caused by a pressure build-up inside the container caused by flammable gases, mainly hydrogen, formed by the chemical reaction of aqueous caustic soda solution with the aluminum alkyl residues. This cleansing of the transport containers is a standard procedure after return from customers and before a new filling. However, in this particular case, even after several attempts it was impossible to completely remove the deposits on the inner wall of the container. Tests aiming at the detection of reactive alkyl residues showed negative results. Thus, the deposits were exposed to an aqueous solution of caustic soda (NaOH). Since no production of heat or gases had been detected over a period of several hours, to increase the effectiveness of the cleaning procedure the container was sealed (against the instruction) and kept revolving around its longitudinal axis on a roller system. After a short time of this process, the container burst, torn apart along the longitudinal axis, while part of is bottom was blown away and damaged a heptane pipeline. The released heptane ignited, and the whole building caught fire. The container had been sealed infringing operating instructions. The substances involved were aluminum, aluminum alkyls, heptane (HCCH), sodium hydroxide (NaOH), hydrogen.
Event Date
September 24, 1998
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Causes
Cause Comments
The immediate cause was the pressure build-up inside the container by formation of flammable gases, mainly hydrogen. The container had been sealed, against what prescribed by operating instructions.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
chemicals transport container, heptane pipeline
Storage/Process Medium
Location Type
Location description
Industrial Area
Operational Condition
Pre-event Summary
The event occurred various failed attempts to perform the cleaning process according to instruction.
Number of Fatalities
2
Currency
Lessons Learned
Lessons Learned
This is an accident where hydrogen was produced accidentally, by reaction of chemical product; therefore, in general, measures aiming at avoiding recurrence of the same type of accidents should concentrate in preventing formation of explosive atmospheres. According to the sources (see References), the following measures were recommended:(1) Cleaning operations of the containers to be performed with a washing medium not reacting with deposits in the containers;(2) To provide the washing station with weighing systems, allowing a determination of residue quantities after washing by weighing the container before and after the cleaning process; (3) To review of the operating instructions.(4) To performing safety training activities.(5) To develop accident scenarios and modelling their consequences; (6) To review the emergency plans.
Event Nature
Emergency Action
Unknown
Release Type
Release Substance
Ignition Source
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Flame Type
Source Category
References
References
Event description in the European database eMARS
https://emars.jrc.ec.europa.eu/en/eMARS/accident/view/61423583-fd94-5ba…
(accessed December 2020)
Event description in the French database ARIA
https://www.aria.developpement-durable.gouv.fr/accident/19461/
(accessed December 2020)