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Clean Hydrogen Partnership

Fire in a refinery plant

Event

Event ID
93
Quality
Description
The event occurred in an alkylation reactor. Due to the rupture of a pipe (probably due to material failure), a power failure took place and the plant was automatically put in hot-stand-by mode. This implied the cut out of fuel feed and energy supply. The plant was gradually cooled down.
After about half an hour, for reasons not yet clarified, a fire started at the outlet of the alkylation reactor.

Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Fire (No additional details provided)
Macro-region
Europe
Country
Germany
Date
Main component involved?
Pipe
How was it involved?
Rupture & Formation Of A Flammable H2-Hc-Air Mixture
Initiating cause
Material Degradation (Generic)
Root causes
Unknown (No additional details provided)
Root CAUSE analysis
The INITIATING cause was the rupture of the pipe feeding into the reactor, probably due to material failure.
How this relates to the development of a fire later is unknown. The investigation report is not available.

Facility

Application
Petrochemical Industry
Sub-application
alkylation process
Hydrogen supply chain stage
All components affected
alkylation reactor, feeding pipe
Location type
Open
Location description
Industrial Area
Operational condition
Pre-event occurrences
The accident occurred during normal operation of the plant. However, fire started after that a shutdown caused by the failure of a pipe.

Description of the facility/unit/process/substances
DESCRIPTION OF THE PROCESS
An alkylation unit is one of the many conversion steps taking place in petroleum refineries. It converts isobutane and low-molecular-weight alkenes (primarily a mixture of propene and butene) into alkylate, a high octane gasoline component. The process occurs in the presence of an acid as catalyst. The feeds contains as well non-condensable gases such as ethane and hydrogen.
(from Wikipedia, https://en.wikipedia.org/wiki/Alkylation_unit)

Emergency & Consequences

Number of injured persons
0
Number of fatalities
0
Currency
Euro
Property loss (onsite)
2500000
Post-event summary
The total establishment and the potential directly involved inventories of hydrogen, methane, benzene and toluene has been estimated in about 10,000 Kg. This figure refers to the whole amount involved in the accident. No data are available about their single amounts.
No people injured. The cost of the material damages estimated between 2 to 5 millions of Deutsch Marks.
Emergency action
none

Event Nature

Release type
gas mixture
Involved substances (% vol)
H2,
CH4,
C6H6,
toluene
Released amount
10 t (total)
Presumed ignition source
Not reported
Flame type
Flash fire

References

Reference & weblink

Event description in the European database eMARS<br />
https://emars.jrc.ec.europa.eu/en/emars/accident/view/f484c24a-cb04-e46… <br />
(accessed September 2020)

Event description in the French database ARIA<br />
https://www.aria.developpement-durable.gouv.fr/accident/801/<br />
(accessed October 2020)<br />

JRC assessment