As I posted, this has happened before:
The
Oppau explosion occurred on September 21, 1921, when approximately 4,500
tonnes of a mixture of
ammonium sulfate and
ammonium nitrate fertilizer stored in a tower silo exploded at a
BASF plant in
Oppau, now part of
Ludwigshafen,
Germany, killing 500–600 people and injuring about 2,000 more.
The plant began producing ammonium sulfate in 1911, but during
World War I when Germany was unable to obtain the necessary
sulfur, it began to produce ammonium nitrate as well. Ammonia could be produced without overseas resources, using the
Haber process.
Compared to ammonium sulfate, ammonium nitrate is strongly
hygroscopic, so the mixture of ammonium sulfate and nitrate clogged together under the pressure of its own weight, turning it into a plaster-like substance in the 20 m high silo. The workers needed to use
pickaxes to get it out, a problematic situation because they could not enter the silo and risk being buried in collapsing fertilizer. To ease their work, small charges of
dynamite were used to loosen the mixture.
This seemingly suicidal procedure was in fact common practice. It was well known that ammonium nitrate was explosive—it had been used extensively as such during
World War I—but tests conducted in 1919 had seemed to indicate that mixtures of ammonium sulfate and nitrate containing less than 60% nitrate were unlikely to explode. On such grounds, the material handled by the plant, nominally a 50/50 mixture, was considered stable enough to be stored in 50,000-tonne lots—more than ten times the amount involved in the disaster. Indeed, nothing extraordinary happened during an estimated 20,000 firings, until the fateful explosion on September 21.
[1]
As all involved died in the explosion, the causes are not clear. However, according to modern sources and contrary to the above-mentioned 1919 tests, the "less than 60% nitrate = safe" criterion is inaccurate; in mixtures containing 50% nitrate, any explosion of the mixture is confined to a small volume around the initiating charge, but increasing the proportion of nitrate to 55-60% significantly enhances the explosive properties and creates a mixture whose detonation is sufficiently powerful to initiate detonation in a surrounding mixture of a lower nitrate concentration which would normally be considered minimally explosive. Changes in humidity and density also significantly affect the explosive properties.
[1]
A few months before the incident, the manufacturing process had been changed in such a way as to lower the humidity level of the mixture from 3-4% to 2%, and also to lower the apparent density. Both these factors rendered the substance more likely to explode. There is also evidence that the lot of mixture in question was not of uniform composition and may have contained pockets of up to several dozen tonnes of mixture enriched in ammonium nitrate. It has therefore been proposed that one of the charges had been placed in or near such a pocket, exploding with sufficient violence to set off some of the surrounding lower-nitrate mixture.
[1]
Two months earlier, at
Kriewald, then part of Germany, 19 people had died when 30 tonnes of ammonium nitrate detonated under similar circumstances. It is not clear why this warning was not heeded.
[1][2]