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Clean Hydrogen Partnership

Explosion at a silicon coating plant

Event

Event ID
530
Quality
Description

An explosion and fire occurred at a chemical plant applying silicone coatings. The blast occurred when some polymethyl hydrogen siloxane was accidentally fed into a reactor, together with the correct feedstock, allyl glycidyl ether.
The two epoxides reacted, overheated and hydrogen burst out of a ruptured pipe into the building, where it mixed with air and exploded.

The 5 workers were caught in the resulting fire. According to the company, the police believed that human error was to blame. Although both chemicals were labelled, they were stored in drums of the same colour.

Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Macro-region
Europe
Country
Germany
Date
Component involved
reactor / oven / furnace / test chamber
Failure mode
internal explosion
Initiating cause
run-away reaction
Root CAUSE analysis

INITIATING cause is the erroneous mixing of a wrong substance (polymethyl hydrogen siloxane) with the correct one (allyl glycidyl ether) in a reactor, causing overheating and hydrogen production.
The accidental event occurred in two step: first the rupture of the reactor due to (probably) to over pressurisation from the runaway reaction, secondly the release, mixing, ignition and explosion of hydrogen in the building.
This could occur because of inadequate chemicals identification so that chemicals were added incorrectly. The ROOT CAUSE could be assigned to shortcoming in procedure and in management failure in identifying worst case scenarios.

Root causes
Date entry in HIAD
01/01/2020

Facility

Application
Chemical industry
Sub-application
paints production
Hydrogen supply chain stage
Location type
Confined
Location
populated area
Operational condition
Description of the facility/unit/process/substances

DESCRIPTION OF THE CHEMICALS INVOLVED
Allyl glycidyl ether is an organic compound used in adhesives and sealants and as a monomer for polymerization reactions. It is formally the condensation product of allyl alcohol and glycidol via an ether linkage. Because it contains both an alkene and an epoxide group, either group can be reacted selectively to yield a product where the other functional group remains intact for future reactions.
[https://en.wikipedia.org/wiki/Allyl_glycidyl_ether#:~:text=Allyl%20glycidyl%20ether%20is%20an,remains%20intact%20for%20future%20reactions.]

Polymethylhydrosiloxane (PMHS) is a sylicon-based polymer characterised by its Si-H bonds. its general structure is [−CH3(H)Si−O−]. It is used in organic chemistry as a mild and stable reducing agent easily transferring hydrides to metal centers and a number of other reducible functional groups.
[https://en.wikipedia.org/wiki/Polymethylhydrosiloxane]

Emergency & Consequences

Number of fatalities
1
Number of injured persons
5
Property loss (onsite)
6.700.000
Post-event summary

Explosion, rupture, damage to equipment and fatality.
Reactors and reaction equipment, pipe and drums. Damage estimated DM 10M $6.7M (1995).

In-depth data

Release type
gas
Involved substances (% vol)
H2 100%
Probable IGNITION SOURCE
Explosion type

References

Sources categories
ARIA
Reference & weblink

ARIA event 7840
https://www.aria.developpement-durable.gouv.fr/accident/7840/
(accesssed December 2025)

ICHEME/MHIDAS event 8527
The ICHEME database is no longer available, but data can be download as PDF for free.
https://www.icheme.org/knowledge-networks/knowledge-resources/safety-ce…
(accessed October 2025)

TAZ news of 17/02/1995
https://taz.de/Explosion-in-Essen/!1520170/
(Accessed December 2025)