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Clean Hydrogen Partnership

Explosion of a reactor for the hydrogenation of ethylene

Event

Event ID
474
Quality
Description

An excess of hydrogen in the reactor vessel resulted in a runaway reaction, causing the vessel to rupture due to overheating. The unbalanced reaction was caused by a reduction of flow of impure ethylene. When the vessel ruptured, air accessed the vessel and ignited spontaneously the process gas.

Event Initiating system
Classification of the physical effects
Hydrogen Release and Ignition
Nature of the consequences
Macro-region
North America
Country
United States
Date
Component involved
reactor / oven / furnace / test chamber
Failure mode
rupture & ignition
Initiating cause
run-away reaction
Root causes
Unknown
Date entry in HIAD
28/01/2026

Facility

Application
Chemical industry
Sub-application
Ethylene, polyethylene, olefins production processes
Hydrogen supply chain stage
All components affected

reactor vessel

Location type
Confined
Location
unknown
Operational condition

Emergency & Consequences

Number of fatalities
0
Number of injured persons
0
Currency
US$
Property loss (onsite)
5.000

In-depth data

Release type
gas mixture
Involved substances (% vol)
H2,
C2H4
Probable IGNITION SOURCE
Explosion type

References

Sources categories
Zalosh
Reference & weblink

Table II - Industrial Incidents of Appendix A of Zalosh and Short
COMPARATIVE ANALYSIS OF HYDROGEN FIRE AND EXPLOSION INCIDENTS
Quarterly Report No. 2 for Period December 1, 1977 - February 28, 1978
https://www.osti.gov/biblio/6566131
(accessed September 2020)