An explosion occurred a the Lurgi electrolysis unit of a chemical factory. The plant suffered extensive damage and one man died. The electrolysis plant produced hydrogen for process use and oxygen as a waste product by electrolysis of potassium hydroxide solution. The investigation concluded that the explosion probably occurred on the oxygen separating drum into which hydrogen had leaked.

A hydrogen leak alarm was received in the control room from the reformer of the hydrogen plant of a chemicals manufacturing facility. The reformed was depressurised and the leak stopped. The leak was reported to the duty officer and nitrogen flushing was started in the reformer. The leak, a 15 mm rupture at the bottom of the tank, was located in a couple of hours. In measurements performed after the nitrogen flushing, hydrogen was still found to be present in the tank, apparently having been left in the catalysts and inside the pocket on the upper section of the tank.

The on-duty field technician noticed a self-sustained ignition in the hydrogen pipes of a sodium chlorate plant. The flare-like flame of less than one metre in height was located in the space above the plant control room right above the exit door. The technician signalled an alarm to the plant control room where the field operator immediately informed the shift supervisor and also the regional emergency response centre.The other people on the site took fire extinguishers from the control room and rushed to the fire scene.

In a metal production company, a leak occurred on valve of a hydrogen line. A new valve was ordered. Almost one month later workers arrived on site to replace the valve. After one hour they heard an explosion. Two men went to investigate and saw flames coming from the hydrogen pipe that was being repaired. They ran outside to isolate the hydrogen lineOne worker had burnt his arm. The hydrogen regulator was burnt and a new one had to be fitted.

A trained plant operator was blending water, sand, anhydrite, lime, cement, PFA and powdered aluminum in a mixing chamber to produce material for making building blocks. All powders are pre-weighed and dosed automatically via a computer controlled system. The mix is then discharged into a car, from which moulds are filled. During a break in production the operator took the opportunity to wash out the mixer in accordance with his work instructions. He did this by manually emptying out the water hopper into the pre-weigh batcher.

A temperature probe on a hydrogen make up gas compressor blew out from its compression fitting. This resulted in a release of hydrogen.

hydrogen gas released from vent stack following failure of relief valve in pressure relief system on bulk hydrogen installation, no ignition and no injuries.

Employee used a small industrial vacuum cleaner on an unnamed process. During this process, hydrogen gas built up from a reaction between sulfuric acid and aluminum swarf. When the vacuum cleaner unit was switched on, the motor supplied the ignition source and the gas exploded in a series of smaller explosions followed by a larger one.

There was a small leak of syngas (a mixture mainly consisting of hydrogen and carbon monoxide) resulting in a localized fire at a bolted flange joint on the outlet carbon steel pipework of the High Temperature Shift Catalyst Vessel.

Iron powder from non-conducting polypropylene IBC was added to EDTA solution at 60 C in reactor. Hydrogen given off, ignited by static.