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Clean Hydrogen Partnership

Release of syngas from an ammonia production unit

Event

Event ID
819
Quality
Description
In an ammonia production unit, a 350-bar leakage of synthesis gas (ammonia + hydrogen)
occurred in the compressor room. The leak was the result of the failure of a weld on a line (2") at the outlet of the compressor.
A flammable cloud formed in the room (15 m x 105 m), 30 to 45 seconds later.
One of the electric motors of the four compressors present was probably at the origin of the ignition, which brought first to an explosion followed by a fire which lasted about ten minutes.
8 people injured, the surrounding buildings were damaged in various ways, as well as the cooling tower and the plant's acid production unit.
Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Macro-region
North America
Country
United States
Date
Main component involved?
Compressor / Booster / Pump (Weld)
How was it involved?
Rupture & Formation Of A Flammable H2-Hc-Air Mixture
Initiating cause
Unknown
Root causes
Root CAUSE analysis
the INITIATING cause was the failure of a weld on a line (2 ") at the outlet of a compressor.
The root cause is unknown

Facility

Application
Chemical Industry
Sub-application
Ammonia production
Hydrogen supply chain stage
All components affected
ammonia reactor, syngas compressor
Location type
Confined
Location description
Industrial Area
Operational condition

Emergency & Consequences

Number of injured persons
8
Number of fatalities
0
Environmental damage
0
Property loss (onsite)
Y
Property loss (offsite)
N
Post-event summary
8 people injured, the surrounding buildings are damaged in various ways, as is the cooling tower and the plant's acid production unit; property damage was estimated at $ 13.4 million.

Event Nature

Release type
gas mixture
Involved substances (% vol)
H2,
NH3
Actual pressure (MPa)
35
Design pressure (MPa)
35
Presumed ignition source
Electricity
Ignition delay
45 s

References

Reference & weblink

ARIA data base <br />
https://www.aria.developpement-durable.gouv.fr/accident/5427/<br />
(accessed December 2025)

JRC assessment