In recent years, there have been serious, even fatal, accidents at biogas production plants in Europe, mainly caused by technical failures, human errors, and weather events.
Although most incidents in this sector each year do not have serious consequences, we suggest that company managers implement risk reduction and monitoring strategies to prevent major accidents from occurring again.
In the first part of this article, we provide an overview of the causes of the most well-known accidents happened in Italy, France, Denmark, and Hungary.
In the second part, we list the main regulations in force in Europe from this year, along with some useful guidelines for proper periodic maintenance of the plants.
The risk assessment of expert insurance consultants, the insurance coverage of the plants, and continuous risk monitoring are indispensable tools for executives and managers to protect the company’s assets and the health and safety of workers.
What have been the most serious recent accidents involving biogas plants in Europe?
In the last 5 years, several accidents have occurred at biogas plants in Europe, highlighting risks related to explosions, fires, and spills.
Below, we provide, as an example, 4 serious incidents that occurred in England, Italy, Hungary, and Denmark.
In Hungary, at Dunaföldvár, in October 2020, there was a significant spill of organic digestate at a major bio-refinery site. The liquid leaked from the plant, causing intense odors in the area, and authorities had to intervene to prevent the flow from reaching the Danube.
Also in Hungary, in Nyírbátor, in October 2021, an explosion at a biogas plant caused the death of three workers. The incident occurred during cleaning operations of a fermentation tank. An explosive mix of methane and oxygen ignited, destroying the structure.
In France, in August 2021, at Ivry-le-Temple, in northern France, during maintenance operations, an explosion occurred inside a 3,900 m³ digester, followed by a fire that involved the double membrane cover.
Fortunately, there were no injuries, but the plant suffered significant structural damage and returned to operation only 8 months after the incident.
In the United Kingdom, in October 2023 near Oxford, a lightning strike hit a storage tank, triggering a massive explosion and a fire visible for miles. The damage to the supporting structures and tanks was extensive.
In Denmark, in 2024, in Flemlose, two young workers lost their lives following the partial collapse of a silo and its roof. In addition to the two deaths, six other people were injured, some seriously.
In Italy, in Coccaglio, in May 2025, a serious workplace accident occurred during the construction of a tank in a new biomethane plant. Two workers were injured, one seriously, due to the overturning of a crane during construction operations.
How many biogas plant incidents occur in Europe on average per year?
Let’s start by saying there is good news for companies that have installed such plants.
Although there are about 80 incidents per year on average in Europe, the vast majority of these incidents (over 90%) do not have serious consequences for people or the environment.
It is also true that particularly significant incidents can occur, like those listed above, so it’s always better to take preventive measures, as we will see below.
What are the main causes of incidents at biogas production stations?
The main causes of incidents at biogas plants in Europe are related to technical failures, human errors, and maintenance deficiencies.
According to industry studies updated to 2025-2026, the most frequent dynamics include:
– technical and design failures
– maintenance errors
– particularly intense weather events.
In the first case, we can include component failures, storage tank leaks, pipe ruptures, or valve malfunctions. Leaks from gasometer domes or distribution networks are common and can lead to the formation of explosive atmospheres.
In the second, we refer to those incidents that occur during repair work, such as the replacement of agitators or welding near digesters without proper precautions. Human error, which must be absolutely avoided, includes incorrect operational procedures or the failure to use personal protective equipment, essential to reduce cases of asphyxiation.
In the third, we include all those unpredictable natural events such as earthquakes, floods, or weather events that can affect biogas production facilities. The major incident that occurred in England, which we mentioned first above, is a striking example.
In case of fire or release of toxic substances, such as methane or hydrogen sulfide, how far do the immediate danger zones extend?
Within 20-30 meters from the plant.
Besides the damage to the individual plant, what are the serious consequences for the entire production?
Companies must absolutely consider that, in addition to direct damage to biogas production plants, there can be serious financial consequences for the entire production, which, following a serious incident, could be halted for weeks.
Let’s give three practical examples for clarity.
Authorities may request the temporary suspension of production following a fatal accident, to allow for the necessary investigations into the cause of the worker’s death.
The same applies if environmental pollution damage requires immediate and costly remediation operations of the areas surrounding the factory, effectively suspending its manufacturing activity.
But beware: fire damage to biogas plants can spread to the production site, as in most cases these alternative energy sources are naturally located in close proximity to the factory.
It is evident that companies must absolutely protect themselves through specific insurance solutions against production stoppage damages: refer here for further insights.
What are the main guidelines to follow to reduce and monitor the risks of fire, explosion, pollution, and workplace accidents?
Starting from January 1, 2026, new obligations regarding sustainability certification and qualification of maintenance technicians for fire protection systems have come into force in Italy and Europe.
In 2026, access to incentives for biogas and biomethane in Europe is strictly tied to compliance with the RED III Directive and increasingly stringent risk management protocols, so companies must implement specific strategies to mitigate environmental impacts and ensure operational continuity.
Specifically referring to the biogas sector, companies are required to conduct a thorough risk analysis according to HAZOP criteria, HAZard and OPerability analysis.
This is a multidisciplinary study that analyzes each “node” of a plant to identify deviations from design and usage conditions that could cause accidents.
Applied to the biogas production sector, it is an essential requirement for obtaining environmental certifications, to reduce damage from machinery shutdowns, and may be required by the same companies as a necessary condition for insurance coverage against fire and machinery failure damages.
Purchasing insurance policies against incidents that may occur at biogas plants is absolutely essential, as only the insurance tool can guarantee the payment of costly indemnities or hefty third-party compensation claims.
However, insurance companies themselves require their clients to monitor the regular operation of the plant for a very simple reason: if serious deficiencies in damage prevention and occupational health and safety are found, the insurance company, having paid the damage, may also decide not to renew the policy for the following year.
Having made this necessary premise, let’s answer the question succinctly below.
We suggest that companies first implement periodic maintenance programs such as annual checks of gas alert and ventilation systems, and triennial checks on ATEX protection systems.
Monitoring the gasometer covers and digester walls to prevent cracks or collapses is another very important activity to be carried out constantly.
With the NIS 2 directive, energy infrastructures (including large biomethane plants) must adopt cybersecurity measures to protect the gas injection network.
Specifically regarding climate risk, companies must demonstrate that they have assessed the risks related to extreme weather events (floods, droughts affecting biomass yield) to ensure the stability of energy supply.
By 2026, most national regulations require that digestate storage tanks be covered to prevent ammonia emissions.
We also recommend:
- installing sensors for flammable and toxic gases with automatic alarms
- ensuring that conductive parts are grounded to prevent ignition from static electricity or lightning
- issuing hot work permits or confined space entries (e.g., digester cleaning), where the risk of asphyxiation or explosion is highest, only to specialized personnel
- clearly marking explosion risk zones with signage
- building containment basins and embankments around digesters to prevent sudden ruptures from causing digestate spills into rivers or aquifers.
- respecting minimum distances from inhabited buildings and flammable storage, or installing firewalls in case of limited spaces.
- conducting periodic inspections with advanced technologies (such as infrared cameras or drones) to identify and repair leaks on valves, joints, and tanks.
In conclusion: the technical visit to the company remains an indispensable tool to reduce the risk of accidents.
In this article, we have only briefly outlined the main causes of the biggest incidents at biogas plants and how important it is to invest in safety, occupational health, and monitoring their regular operation.
The technical visit of insurance consultants and technicians remains a strategic tool for companies.
Thanking to their long professional experience, they can identify the most serious risks in time and the necessary urgent measures to prevent damage to the environment and company assets, production stoppages, and hefty compensation claims from the families of a worker who died at the company.