Explosion in the Hydrogenation Reactor of a Chemicals Manufacturing Plant
Explosion in a chemical manufacturing plant for the pharmaceutical and cosmetics industries, classified as Seveso high level, The explosion occurred in the hydrogenation reactor, when opening two buffer tanks to clean the reactor the after hydrogenation using a catalyst (ruthenium on coal). Following the explosion, the operator initiated the emergency plan, evacuated personnel and secured the area. Two operators were injured. According to the ARIA source, the explosion was probably be due to the presence of hydrogen in the reactor, because the nitrogen purging was not performed despite the procedures in place. The flammable mixture created by the entrance of oxygen at the opening of the buffers, was then ignited by a hot spot formed by a catalyst deposit which probably had become pyrophoric after activation.
Event Date
December 14, 2018
Record Quality Indicator
Region / Country
Event Initiating System
Classification of the Physical Effects
Nature of the Consequences
Causes
Cause Comments
Immediate cause of the explosion was the presence of hydrogen when opening to air the tank. Intermediate cause was the failing to apply the procedure to purge the tank with nitrogen.Root cause is unknown, because it is not known why the procedure was no followed.
Facility Information
Application Type
Application
Specific Application Supply Chain Stage
Components Involved
hydrogenation reactor, buffer tank
Storage/Process Medium
Location Type
Location description
Industrial Area
Pre-event Summary
The procedure for the reactor purging was not followed.
Currency
Lessons Learned
Lessons Learned
The operator introduced the following two improvements 1. Review and re-assessment of the operative procedures2. new training of the workers.An additional measure, not mentioned in the ARIA report, would come from the answering the question on why the procedure was not followed, and what can be put in place to guarantee/monitor that they are followed in the future.
Event Nature
Emergency Action
Following the explosion, the operator initiated the emergency plan, evacuated personnel and secured the area.
Release Type
Release Substance
Ignition Source
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/52794/
(accessed September 2020)