Can CO₂ Tanks Explode?

CO₂ tanks can explode if exposed to extreme heat, physical damage, or over-pressurization. While these incidents are relatively rare, they can result in serious injuries, property damage, and even fatalities.

In this guide, we’ll explore the main causes of CO₂ tank explosions. We’ll also show you some real-world incidents that highlight these risks and discuss the safety measures that can prevent catastrophic failures.

Overpressurization from Heat and Temperature Changes

The main cause of CO₂ tank explosions is overpressurization due to temperature increases. CO₂ has a critical temperature of 87.9°F, and pressure inside cylinders rises dramatically as temperatures climb.

A standard 20-pound CO₂ cylinder reaches approximately 1,100 psi at 87.9°F. When exposed to 120°F temperatures, that same cylinder can reach nearly 2,000 psi, which may exceed the maximum allowable working pressure.

This temperature-pressure relationship is particularly dangerous in hot climates like California’s Central Valley, where summer temperatures routinely exceed 100°F. Storage areas without proper climate control can create conditions ripe for cylinder failure.

The expansion of liquid CO₂ inside the tank leaves less room for the gas phase, creating additional pressure. This thermal expansion can quickly push pressures beyond safe limits when cylinders are stored in:

• Direct sunlight
• Vehicle trunks
• Poorly ventilated areas

Overfilled cylinders make the issue even worse. Tanks designed to be filled to 68% of their water capacity can vent through safety devices at temperatures as low as 70°F when filled to 95% capacity, and may rupture at even lower temperatures if safety devices fail.

Safety Device Failures and Mechanical Issues

To prevent explosions, pressure relief mechanisms like bursting discs are designed to release pressure at 190 bar (2,756 psi). Still, these safety devices can fail when tampered with or improperly maintained.

Regular hydrostatic testing and visual inspections help identify mechanical issues before they become catastrophic. Unfortunately, many facilities skip these routine maintenance procedures due to cost or scheduling constraints.

Incident Prevention Through Proper Storage and Maintenance

Preventing CO₂ tank explosions requires strict adherence to storage temperature limits and regular maintenance schedules. Cylinders must be stored below 125°F and secured with chains or noncombustible barriers to prevent tipping.

OSHA also mandates specific storage requirements, including proper ventilation and separation from incompatible materials. As CO₂ accumulates at floor level, gas detection systems must be positioned accordingly.

Floor-level CO₂ detectors should be installed in all storage areas, with alarms set well below dangerous concentration levels. Ventilation systems must direct any leaked gas outdoors rather than allowing accumulation in confined spaces.

Regular inspection schedules should verify the integrity of:

• Safety discs
• Valves
• Cylinder walls

Any signs of corrosion, dents, or unauthorized modifications require immediate attention and potential cylinder replacement.

Finally, training programs must emphasize proper handling techniques and emergency response procedures. Workers should understand the specific risks of CO₂, including its invisible and odorless nature that makes leaks difficult to detect without proper equipment.

Tread Carefully With CO₂ Tanks

While CO₂ tank explosions are preventable, the consequences of failure can be severe. The combination of high pressures, temperature sensitivity, and the gas’s asphyxiation risks requires constant vigilance from anyone working with these systems.

Investing in proper storage conditions, regular maintenance, and comprehensive training programs protects both personnel and facilities from these serious hazards.

Tyler O'Brien

Tyler is a results-driven marketing professional specializing in the industrial gases and equipment industry, bringing his 10 years of technical expertise and digital marketing acumen to the complex industrial gas B2B environment.