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Case Study: Internal Explosion and Severe Damage of a High-Pressure Scrubber (Urea Plant)

This 30-minute training walks through a real incident in a urea plant: an internal explosion inside the high-pressure scrubber following improper shutdown actions and a build-up of a flammable gas mixture. You’ll see what happened, why it happened, and how to prevent a repeat—framed within a practical Process Safety and Operational Excellence perspective.

What you’ll learn

Technical sequence of events leading to ignition inside the HP Scrubber

Immediate and underlying causes (procedural, control, and equipment factors)

Consequences: equipment damage, safety device response, unplanned repairs

Actionable lessons for shutdown, depressurisation, purging, and safeguards

How to embed these lessons in your Process Safety and Operational Excellence programmes

Who should watch
Operators, process engineers, maintenance teams, equipment vendors and solution providers working with urea and ammonia units.

Duration: 30 min

Authors / Trainers
Fertilizer Academy Team — the premier online training platform for the fertiliser industry.

About Fertilizer Academy
We deliver end-to-end training for ammonia and urea plant operators—from new hires to supervisors—aimed at preventing operational errors and avoiding process incidents. Our courses are developed by an independent group of senior specialists with deep expertise across ammonia, urea, nitric acid and ammonium nitrate. Topics include Plant Operation, Process Safety, Incident Analysis & Case Studies, Corrosion & Materials, High-Pressure Equipment, and more. Customised programmes and multiple languages available.

Explore more: https://fertilizer.academy/

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