THE FIRE AND EXPLOSION RISKS ASSOCIATED WITH ETHANOL PRODUCTION AND TRANSPORTATION

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.

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.

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.

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

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.

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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