A fire broke out in the research and development centre of a pharmaceutical plant during the preparation of a reaction in the autoclave area of a building. This building, dedicated to development tests, is divided into 3 areas: laboratory, autoclave area and order area. The hydrogenation in question involves 2.5 kg of a synthesis intermediate in 14 l of ethanol in the presence of a catalyst with 5% platinum on dry charcoal (115 g) in a 20 l autoclave (inspection in May 2003). At the time of the accident, the technicians were loading the solution of the product in 2.5 l of ethanol into the reactor with nitrogen bubbling. When loading the 15 g of powder catalyst, they noticed that the substance was glowing in the funnel. The alcohol ignited following its addition from a 10 l drum. Two employees were burned by splashes, one seriously on the face and the other on the hands and feet. The fire spread into the room. Black smoke was generated by the combustion of solvent and plastic materials (drums, etc.). The raw material and 100 g of catalyst were recovered intact. The actions of the fire-fighters, who arrived within 10 minutes, limited the impact of the fire on the environment.

Evacuating the building meant that no one could use the shower, which meant that they had to use the facilities in another room. The operation of the hydrogenation workshop was suspended until the inspection authorities for classified facilities had allowed the resumption of activities.

The catalyst may have reacted with the oxygen in the air when it was being introduced and caused the alcohol to ignite. Without anticipating the findings of the coming investigations, the operator is considering the renovation of the involved building, drafting work instructions, holding ‘hazard vetting’ meetings before any operation, displaying guidelines in the hydrogenation room, ensuring the presence of a third chemist during the loading/unloading of substances, training all of the site’s chemists on hydrogenation reaction hazards, researching systems for introducing ‘sensitive’ catalysts (containment principle), doubling the number of showers to be installed outside, installing a specific alarm in the building and carrying out a feasibility study on the installation of a automatic fire extinguishing system and the remote shut down of the hydrogen, electricity and compressed air supplies.