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Clean Hydrogen Partnership

Small fire in the desulphurisation unit of a refinery

Event

Event ID
1228
Quality
Description
The incident occurred in the new Residue Upgradation Facility unit of the refinery, which converts the heaviest oils from crude oil into high-quality, cleaner fuels such as Euro 6 diesel. The unit was was still under construction.
Hydrogen gas leaked from a piping connected to a pressure transmitter of the hydrogen compressor and caught fire due to static charges. The automatic sprinklers brought down the fire immediately, after which fire fighters reached the spot and brought the situation under control. No injury.
Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Fire (No additional details provided)
Macro-region
Asia
Country
India
Date
Main component involved?
Compressor / Booster / Pump (Pipe)
How was it involved?
Leak & Formation Of A Flammable H2-Air Mixture
Initiating cause
Material Degradation (Generic)
Root causes
Unknown (No additional details provided)

Facility

Application
Petrochemical Industry
Sub-application
desuphurisation unit
Hydrogen supply chain stage
Hydrogen Compression (No additional details provided)
All components affected
pressure gauge, piping
Location type
Unknown
Operational condition
Pre-event occurrences
There were no workers at the time of the accident. During working times, 200 workers, inlcuding contractors, would be in the surroundings.
Description of the facility/unit/process/substances
DESCRIPTION OF THE PROCESS
In a Residue Upgradation Facility (RUF) process, hydrogen acts as a reagent in hydrocracking and hydrotreating reactions to convert heavy hydrocarbon residues into lighter, higher-value products like gasoline and diesel. Specifically, hydrogen:
• Breaks down large molecules: Hydrogen, in conjunction with a catalyst, breaks the strong carbon-carbon bonds in complex, long-chain hydrocarbon molecules, converting them into simpler, shorter-chain molecules.
• Removes impurities: Hydrogen reacts with heteroatoms like sulfur and nitrogen in the residue, removing them in the form of hydrogen sulfide (H₂S) and ammonia (NH₃), respectively.
• Prevents coke formation: Hydrogen saturates reactive species and inhibits coke formation by hydrogenating coke precursors, which can cause issues in the process.
• Increases distillate yields: By upgrading the heavy residue into lighter fractions, hydrogen contributes to maximizing the yield of more valuable products, improving refinery profitability.
{https://environmentclearance.nic.in/writereaddata/Online/TOR/31_Aug_2018_1557428738TGB9AH7BriefSummary.pdf]

Emergency & Consequences

Number of injured persons
0
Number of fatalities
0
Property loss (offsite)
0

Event Nature

Release type
gas
Involved substances (% vol)
H2 100%
Presumed ignition source
Static electricity

References

Reference & weblink

Deccan Cronicle new of 19 Septemebr 2025<br />
https://www.deccanchronicle.com/southern-states/andhra-pradesh/hydrogen… />
(accessed November 2025)

The Time of India news<br />
https://timesofindia.indiatimes.com/city/vijayawada/fire-due-to-gas-lea… />
(accessed Novemebr 2025)

JRC assessment