Tag: Plant Incidents

Two dam failures at the Morowali industrial park in Indonesia have killed three people. On March 16, during heavy rains, the PT Huayue Nickel Cobalt tailings storage facility at the Morowali industrial park failed, and tailings flowed into the Bahadopi River. The breach flooded facilities at the industrial park and the village of Labota. Five days later another tailings dam inside the industrial park, owned by PT Qing Mei Bang (QMB) New Energy Materials, collapsed, killing three workers. The affected tailings facilities store acidic waste from high pressure acid leaching (HPAL). It is estimated that for every ton of nickel, HPAL processing generates 150-200 tons of tailings. The affected facilities use filtered tailings, where some of the water is removed from the tailings before they are placed the dam. However, heavy rains, landslips and seismic activity appear to have affected the stability of some of the dams.

Russian media reports suggest that a large scale Ukrainian drone strike on February 3rd attacked a number of oil and gas processing facilities, including Gazprom’s Astrakhan Gas Processing Plant. Video of the site showing fires burning were posted to social media. Astrakhan is one of the largest sulphur producing sites in Russia, with an output of around 3.5 million t/a in 2024. The Moscow Times reported that production had been shut down at the site, and would likely remain so for “several months”.

In recent years, extensive and severe internal attack has been observed of carbon steel equipment and lines in aqua ammonia service at several Yara manufacturing sites across the globe. In all cases, the damage has a distinct flow-accelerated corrosion (FAC) signature which challenges the current understanding of FAC. All features typically observed for this kind of damage mechanism, that seem to be specific to the NH3 recovery section of ammonia plant, are reported. Upgrading the material of construction for this unit, will solve this failure mode, but a leak would potentially generate health and safety problem for the release of ammonia.

Safety in sulphuric acid plants is a well-known and widely discussed topic. Industry turnover is a reality, and keeping new employees informed of hydrogen safety procedures is key to keeping plants fully operational and incident free. Walter Weiss of Elessent Clean Technologies discusses the steps facilities need to take to prevent hydrogen incidents.