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Clean Hydrogen Partnership

Explosion in a aluminium manufacturing plant

Event

Event ID
1251
Quality
Description
An explosion occurred at the fume treatment unit of a foundry. The fumes contained chlorine, used in the metal treatment process. The treatment unit function by spraying water and caustic soda. The facility was put in safe mode and the furnaces containing metal were shut down. Restarting the furnaces was subject to approval by the classified installations inspectorate.

Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Macro-region
Europe
Country
France
Date
Main component involved?
Treatment System
How was it involved?
Internal Explosion (H2-Cl2 Mixture)
Initiating cause
Run-Away Reaction
Root causes
Root CAUSE analysis
The event was probably due to the reaction between the residues in the extraction ducts and the caustic soda, which caused a release of hydrogen. A similar event had occurred at the site seven years earlier, which had been attributed to the excessive presence of metallic dust in the unit, which in contact with water produced hydrogen (See HIAD_1250 based on ARIA 50150). At that time, several improvements were introduced to the treatment unit, to be able to monitor and detect earlier the conditions under which hydrogen is accidental produced.

Facility

Application
Steel And Metals Industry
Sub-application
Aluminium processing
Hydrogen supply chain stage
Location type
Open
Operational condition

Emergency & Consequences

Number of injured persons
0
Number of fatalities
0
Property loss (onsite)
low
Official legal action
Restarting the furnaces was subject to approval by the classified installations inspectorate.

Event Nature

Release type
gas-dust mixture
Involved substances (% vol)
H2
NaOH
aluminium dust
Actual pressure (MPa)
n.a.
Design pressure (MPa)
n.a.
Presumed ignition source
Hot surface

References

Reference & weblink

Event nr 61581 of the French database ARIA<br />
https://www.aria.developpement-durable.gouv.fr/accident/61581/<br />
(accessed December 2025)

JRC assessment