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Biogas plants numbers are increasing worldwide, but their safety record is rarely investigated. This paper analyzes 75 occurrences of various types of accidents in biogas plants worldwide between 1990 and 2023. The study comprehensively reviewed accident reports and research literature with input from plant operators and safety experts. We aim to identify the common causes and consequences of accidents (occurrences) and suggest preventive measures to improve safety. The occurrences’ primary causes were component failure > maintenance error > natural and technological disasters (NaTech) > equipment failure > operational error > no personal protective equipment (PPE). The most common occurrences were gas explosions 69.3%, toxic gas releases (biohazard) 21.3%, asphyxia (biohazard) 4%, malfunctioning (electric and mechanical hazard) 2.7%, and fires 2.7%. The accident consequences ranged from minor injuries (76) to fatalities (51) and extensive property damage. Lack of PPE and gas pipelines (mechanical and biohazards) correlated positively and significantly (R2 = 0.70), while operational errors and asphyxia (biohazard) scenarios correlated positively and moderately (R2 = 0.55). The plant design, operating procedures, and maintenance practices strongly influence the occurrences’ likelihood and severity. This study provides valuable insights for stakeholders, researchers, and policymakers interested in promoting biogas’ safe and sustainable development. Future studies should investigate the relationship between plant size and accident frequency and assess the effectiveness of safety management and risk assessment methodologies in mitigating such occurrences.
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