THE FIRE AND EXPLOSION RISKS
ASSOCIATED WITH ETHANOL PRODUCTION AND TRANSPORTATION
In
the last fifteen years, the production of ethanol has increased dramatically
due to the demand for ethanol-blend fuels. Current production (November
2014) in the United States is almost 15 billion gallons (14.932
billions). On December 19, 2007, the Energy Independence and Security Act
of 2007 was signed into law.
This comprehensive energy legislation amended the Renewable Fuels Standard (RFS) signed into law in 2005, growing the RFS to 36 billion gallons in 2022. There are 213 nameplate refineries, with additional refineries being proposed/expanded. Most the ethanol refineries are located in the Midewest and upper Midwest. Ethanol is produced by fermentation and distillation processes.
The most common ethanol concentration leaving a biorefinery is denatured fuel ethanol which consists of 98% ethanol and 2% denaturing agent (rust inhibitor). Natural gasoline is also mixed with the alcohol, prior to shipment.
This comprehensive energy legislation amended the Renewable Fuels Standard (RFS) signed into law in 2005, growing the RFS to 36 billion gallons in 2022. There are 213 nameplate refineries, with additional refineries being proposed/expanded. Most the ethanol refineries are located in the Midewest and upper Midwest. Ethanol is produced by fermentation and distillation processes.
The most common ethanol concentration leaving a biorefinery is denatured fuel ethanol which consists of 98% ethanol and 2% denaturing agent (rust inhibitor). Natural gasoline is also mixed with the alcohol, prior to shipment.
The
yellow circles indicate refineries under construction. The green circles
are operational ethanol plants.
Denatured
ethanol is largely shipped from production facilities by rail and is now the
largest volume hazardous material shipped by rail.
Large
volumes of ethanol are commonly shipped by unit trains, up to 3.5 million
gallons, and the larger barges can transport up to 2.5 million gallons.
In Massachusetts, two to three ethanol unit trains currently travel
through the state per week, as well as an ethanol barge per week. The
number of trains and barges transporting denatured ethanol (95% - 98% ethanol)
through the state are anticipated to increase in the future, especially if the
use of higher ethanol blends becomes more prevalent.
The high volume of ethanol transported and the differences in the chemical properties, and the fate and transport of ethanol as compared to standard gasoline, led to the need for additional consideration of spill response actions. In particular, this document considers the assessment and response actions for rail and barge spills of denatured ethanol.
The high volume of ethanol transported and the differences in the chemical properties, and the fate and transport of ethanol as compared to standard gasoline, led to the need for additional consideration of spill response actions. In particular, this document considers the assessment and response actions for rail and barge spills of denatured ethanol.
Ethanol
is a flammable colorless liquid; a polar solvent that is completely miscible in
water. It is heavier than air, and has a wider flammable range than gasoline,
with a Lower Explosive Limit (LEL) to an Upper Explosive Limit (UEL) range of
3.3% to 19%. The flash point for pure ethanol is 55°F, and for denatured
ethanol it is much lower (-5°F).
Ethanol is still considered a flammable liquid in solutions as dilute as 20%, with a flash point of 97°F. At colder temperatures (below about 51°F), the vapor pressure of ethanol is outside the flammable range. Denatured ethanol is shipped with a flammable liquids placard and North American 1987 designation.
Ethanol is still considered a flammable liquid in solutions as dilute as 20%, with a flash point of 97°F. At colder temperatures (below about 51°F), the vapor pressure of ethanol is outside the flammable range. Denatured ethanol is shipped with a flammable liquids placard and North American 1987 designation.
Here
is a partial list of some fires and explosions involving ethanol plants across
the United States. Due to the flammable and explosive nature of the
process, these fires and explosions occur at some frequency.
ETHANOL PLANT EXPLOSION OR FIRE
PLANT
|
LOCATION OF
FIRE/EXPLOSION
|
DATE
|
Arkalon
Energy LLC, Liberal, Kansas
|
A corn dryer
caught fire and exploded. The
combustion chamber of the dryer exploded due to natural gas.
|
29-Jun-14
|
Green Plains
Renewable Energy, Fergus Falls, MN
|
A hydraulic
pump which controls the damper in the dryer building of the Green Plains
Renewable Energy plant failed
|
13-Mar-14
|
Flint Hill
Resources, Arthur, Iowa - Platinum Ethanol Plant, 2585 Quail Avenue, Arthur,
IA
|
A distilled
grains dryer exploded, damaging a unit of the building.
|
17-Jul-14
|
Badger State
Ethanol Plant 820 W. 17th Street
P.O. Box 317 Monroe, WI 53566 |
small fire
and explosion in silo
|
23-06-07
|
Ethanol of
Florida, E 1705 Mann Rd , Bartow FL Polk - County
|
a tank
containing alcohol exploded near the rear of an ethanol plant
|
24-04-09
|
Abengoa
Bioenergía , 395 Bissell St. Madison, IL, 63060, USA
|
Men were
working near a container in a maintenance shed when the container exploded.
|
11-04-11
|
Lincolnway Energy,
59511 West Lincoln Highway, Nevada, Iowa
|
Explosion at
the ethanol plant. A power surge
caused a steam pipe to burst, burning the workers who were performing
maintenance nearby
|
11-11-07
|
American AG
Fuels, Defiance, Ohio
|
unknown reason
for blast, but happened in loading area
|
04-01-08
|
Appomattox
Bio Energy Plant, 701 S. 6th Avenue, Hopewell Virginia 23860
|
vapors
back-up and the vapors were in a device that has a burner in it and so the
vapors ignited
|
09-09-10
|
Chief
Industries, 4225 E South St. • PO Box 488 • Hastings, NE 68901
|
the men
opened the door of a grain grinder while doing maintenance and a small
explosion occurred.
|
Mar. 6, 2009
|
Poet Ethanol
Plant , 27716 462ND AVE. CHANCELLOR, SD 57015
|
issue with
feed dryer. Worker were taking downt he dryer when a a small amount of dust
ignited.
|
24-08-10
|
Pinal Energy,
38585 W Cowtown Rd Maricopa, AZ 85139
|
the explosion
was possibly the result of corn by-product dust particles that were ignited
by a heating system used in the ethanol-producing drying process.
|
09-10-09
|
Central
Minnesota Ethanol Co-op in Little Falls, Minn.
|
the damage
was contained to a biomass gasification system
|
03-10-07
|
Chippewa
Valley Ethanol Co. 270 20th St. NW, Benson, MN 56215
|
A tank
holding 40,000 gallons of corn mash, exploding with a "whoosh and a
flash"
|
Oct. 22, 2003
|
A
LyondellBasell US ethanol 625 East US Highway 36,
Tuscola, IL 61953 |
plant rocked
by an explosion on Monday
|
22-03-10
|
Collingwood
Ethanol plant
|
fire in silo
|
13-05-09
|
Amaizeingly
Green L.P formerly Collingwood Ethanol
|
The company
was convicted of a number of charges laid by
the MOE related to odour and noise issues. |
2009
|
Tharaldson
ethanol plant 3549 153rd Avenue SE Casselton, ND 58012
|
contained to
a dust collection bin.
|
28-02-09
|
Constellation
New Energy Inc
3201 West Calvert Street South Bend, IN 46613-1010 |
fire not
clear
|
12/30/10
|
Bushmills
Ethanol, Atwater, MN 56209
|
fire on
conveyor belt
|
11/04/2010
|
Bushmills
Ethanol, Atwater, MN 56209
|
natural gas
leak
|
10/24/2009
|
Poet
Refining, Caro, MI 48723
|
fire in the
ductwork between the dryers and thermal oxydizer caught fire
|
10/13/10
|
Pinal Energy,
38585 W Cowtown Rd Maricopa, AZ 85139
|
explosion at
a grain elevator
|
12/29/08
|
Glacial Lakes
Energy
|
fire in large
corn dryer
|
12/23/08
|
East Kansas
Agri Energy
|
Ethanol
Explosion
|
12/16/08
|
anildra
Ethanol Plant, Bomaderry, NSW 2541
Australia |
explosion
|
12/10/2008
|
Greater Ohio
Ethanol, Lima OH
|
dust fueled
fire in duct work
|
11/11/2008
|
Central
Minnesota Ethanol Co-op, Little Falls, Minn.
|
explosion in
a wood chip storage silo
|
10/29/08
|
Poet
Biorefining Michigan Ethanol
|
fire in hot
spots in the ductwork
|
9/23/08
|
Glacial Lakes
Energy, Mina, SD 57451
|
electrical
motor blamed for the fire at the bottom of a grain bin
|
8/30/08
|
Abengoa
Bioenergy, York, NE 68467
|
fire in duct
work
|
07/02/2008
|
Andersons
Albion Ethanol, Sheridan Township, MI
|
explosion in
the dryer
|
6/27/08
|
Poet
Biorefining Mitchell, Loomis, S.D
|
flash fire,
|
01/03/2008
|
Pine Lake
Corn Processors, Steamboat Rock, IA 50672
|
Dryer
explosion
|
2007-dec
|
Central
Minnesota Ethanol Co-op in Little Falls, Minn.
|
explosion in
silo/biomass gasification system
|
10/27/07
|
AGP Ethanol
plant, Hastings
|
fire in
soybean meal dryer
|
7/29/06
|
Big River
Resources, West Burlington, IA
|
fire in bin
that is used to dry animal feed
|
9/21/05
|
Heartland
Grain Fuels, Aberdeen, SD
|
dryer fire
|
11/14/04
|
Michigan
Ethanol/Poet, Caro, MI
|
dryer fire
during routine dryer shutdown
|
5/24/04
|
Great Plains
Ethanol/Poet, SD
|
power outage/
fire stated when feed ignited
|
3/14/04
|
Gopher State
Ethanol/ out of business
|
a piece of
insulation fell into a heated area, setting the roof
on fire |
7/26/03
|
Tri-County
Ethanol/North Country Ethanol, S. Dakota
|
fire and
explosion in the distillation area
|
12/31/02
|
Gopher State
Ethanol, Saint Paul, MN
|
fire in grain
drying unit
|
06/05/2002
|
Gopher State
Ethanol, Saint Paul, MN
|
fire in grain
drying unit
|
3/23/02
|
Corn Plus,
Winebago, MN
|
older dryer
fire
|
11/30/01
|
Heartland
Grain Fuels, Aberdeen, SD
|
fire started
after a valve allowed 200 proof raw alcohol to
drain onto the floor and run out an open door. A spark from welding equipment used by a crew working on the second floor of the building ignited the alcohol. |
8/23/2000
|
New Energy,
South Bend, Indiana
|
fire
contained to the bag house. Spontaneous combustion the
cause |
3/21/2000
|
Minnesota
Energy, Buffalo Lake, MN
|
fire in the
dryer
|
11/06/1998
|
Yokkaichi,
Mie, Japan
|
explosion in
recycle gas piping near reactor due to erosion
|
05/02/1997
|
Cornhusker
Energy Lexington LLC, NE
|
natural gas
rupture
|
12/24/2008
|
Manildra Park
Petroleum, Australia
|
1/29/2004
|
|
Delta Oil
Mill, Greenwood, Miss
|
grain fire
|
06/27/2011
|
Surat India
|
leak in
ethanol pipeline
|
11/23/2003
|
Equistar
Chemicals, Tuscola, Illinois
|
confined to a
furnace
|
03/23/10
|
Agri-Energy,
1304 S. Main St., Garnett, Kansas
|
12/17/2008
|
|
Lincolnland
Agri- Energy, Palestine, Ill
|
dryer
|
12/14/09
|
boiler or
maintenance area explosion, caused severe damage at the plant
|
9-Jan-13
|
|
fire in a
storage unit used to house grain and wheat at the FUEL Ethanol Plant in
Pelham.
|
15-Sep-11
|
|
The fire was
caused after a piece of burning conveyor belt fell into the bin. Fire burns conveyor and 750,000 bushel
grain.
|
4-Nov-10
|
|
explosion at
an ethanol tank sent flames 40 feet in the air
|
24-Apr-09
|
|
Explosion and
fire in a germ dryer and bagging processor. But the fire extended into the
grain handling ductwork and spread to other pieces of equipment
|
19-Jan-09
|
|
The power at
the facility went down. The system
that dries feed to make ethanol shut down, and heat inside the building
caused some of the grain to start on fire.
The lack of power made it difficult to fight the fire.
|
14-Mar-04
|
|
the
distillery at an Atchison alcohol plant exploded, throwing debris across Main
Street and shaking surrounding buildings.
|
14-Sep-02
|
Train
accidents do have the potential to do more than puncture a tank car. Ethanol
train accidents, for example, have resulted in multiple car derailments that
have sparked massive fireballs. In one of the worst cases, in Cherry
Valley, Illinois, in 2009, a derailment of 13
ethanol cars and resulting fire killed one person at a rail crossing and
injured seven others, led to the evacuation of 600 homes, and caused $8 million
in damages.
A
number of large volume ethanol incidents have occurred. Some of these have
resulted in significant fires, most of which have been allowed to burn. Water
has been used in some incidents, primarily to protect nearby structures or
tanks. Alcohol-resistant foam has also been used, primarily to extinguish
fires within tanker cars.
Sampling and analysis of environmental media that has occurred in connection with spill response activities have shown impacts related to these spills, although they are generally of relatively short duration. The most significant documented impact was a large fish kill that occurred in Kentucky as a result of a bourbon spill. This effect was related to oxygen deficiency resulting from ethanol biodegradation, rather than direct toxicity. Another fish kill was observed subsequent to a spill in Illinois, but it has not been definitively attributed to the spill.
Sampling and analysis of environmental media that has occurred in connection with spill response activities have shown impacts related to these spills, although they are generally of relatively short duration. The most significant documented impact was a large fish kill that occurred in Kentucky as a result of a bourbon spill. This effect was related to oxygen deficiency resulting from ethanol biodegradation, rather than direct toxicity. Another fish kill was observed subsequent to a spill in Illinois, but it has not been definitively attributed to the spill.
Summary
of Ethanol Incidents Nationwide between 2008 & 2014
Reviewed
40 incidents where ethanol or an unidentified hazardous material was released.
·
25 incidents involved release of ethanol
·
14 incidents involved release of unknown hazardous material
·
Four incidents had detailed reports available from the FRA or National
Transportation Safety Board (NTSB). Remaining information collected from
media sources and crash reports.
·
Improper track inspections/maintenance and lack of communication were the major
causes of the derailments.
·
Train speed and DOT-111 railcar design contributed to the release of ethanol.
One event resulted in a fatality, two events resulted in personal injury.
·
Average cost of damages to railroad property is $1,900,000 per incident.
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