Explosion in an Electrolyzer Producing Chlorine
Explosion in an electrolyzer producing chlorine The explosion occurred after the opening of an auxiliary circuit-breaker. The opening of the auxiliary circuit breaker trigger the shut down of the pumps and chlorine compressor. Two of the circuit breakers open but one remained closed providing the electrolyzer with 20 kA, while the mercury and brine pumps and the chlorine compressor were shut down. The explosion occurred when the auxiliary circuit breaker was finally closed 15mn later, following various unsuccessful attempts.The reason for the auxiliary circuit breaker to open was an overload of the electric transformer, aging of the circuit breaker and high temperature. It is not clear what caused the specific circuit breaker, which was used since 2 years and in good state, to remain open. One hypothesis is that the 50kA neighboring line lead to a magnetization of the circuit breaker.A plausible cause for explosion is the formation hydrogen by the acidic attack of the electrolyzer cells and production of sodium and potassium hypochlorite. The still running chlorine compressor extracted the hydrogen and reacted with the chlorine remaining in the pipe. This hypothesis is confirmed by the small pressure increase in the cells and the absence of explosion in the electrolyzer cells. The formation of hypochlorite and hydrogen was possible by the reaction of the salt and the water contained in the brine due to the absence of mercury to fix the sodium and the potassium.
Event Date
June 26, 1995
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Cause Comments
The immediate cause was a technical reason, the failure of a circuit breaker to act and open the circuit of one electrolysis unit, while the other units were shut down. The operator did not realize this abnormal situation and the auxiliary system continued operating while they should have been shut down as well.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
electrolyzer, circuit breaker
Storage/Process Medium
Location Type
Location description
Industrial Area
Operational Condition
Pre-event Summary
The circuit breaker which did not operate was in good state and only two years old.
Consequences
Number of Injured Persons
4
Currency
Lessons Learned
Lessons Learned
Following the analysis of the incident, electrical and magnetic problems seemed the probable initial cause. The plant operator decided to modify the electrical system improving power load rejection, protection against electromagnetism.
Event Nature
Emergency Action
Unknown
Detonation
No
Deflagration
No
High Pressure Explosion
No
High Voltage Explosion
No
Source Category
References
References
Event description in the French database ARIA
https://www.aria.developpement-durable.gouv.fr/accident/22101_en/?lang=…
(accessed October 2020)