Ethanol Plants: How to Reduce Explosion and Accident Risks

Ethanol and sugar plants represent one of the main sectors of the Brazilian economy, accounting for approximately 3.28% of the national industry’s production value, according to IBGE.

However, this same sector is one of the leading causes of workplace accidents in the country. In the state of Alagoas, for example, 59% of accidents are caused by the sugarcane industry.

With the industrial economy being impacted by severe accidents, discussing workplace safety has become more important than ever. Therefore, based on our visits to the country’s largest sugar-alcohol plants, we have listed the main risk areas in the sector. Check them out:

1. Harvest

The first phase of sugar-alcohol production, harvesting presents significant accident potential. Since it is still performed manually in much of the country, implementing safety measures to protect workers is essential.

In addition to personal protective equipment, proper worker training in equipment usage is also crucial.

2. Loading and Transportation

This stage of production is where most accidents in the sector occur, including rollovers, collisions, and overturns. These types of incidents are extremely dangerous, as they can cause leaks and even explosions.

Therefore, this phase deserves considerable attention. Having a well-lit environment, for example, is an effective way to prevent these accidents. Proper lighting ensures worker visibility, allowing them to drive more carefully and avoid collisions.

However, not just any equipment can be used in this type of location. Intrinsically safe devices are ideal for hazardous situations like these, being specifically designed to prevent explosions.

3. Plant

The final stage, where sugarcane is transformed into ethanol and sugar, also presents numerous risks, particularly of explosions. Since this involves handling liquid fuel in confined spaces (such as tanks and towers), any small leak or spark can cause significant damage.

The fermentation, distillation, and storage phases require the most attention. Additionally, activities such as inspection and chemical cleaning of tanks are quite hazardous and must be performed with specialized equipment.

Therefore, in addition to conducting gas tests before entering the location, using EX explosion-proof lamps is essential to ensure safe lighting (and visibility) for the work.

Consequently, despite their accident potential, ethanol and sugar plants can be safe work environments with the proper precautions. Above all, stay informed about all risks and protective measures. Furthermore, always work with quality equipment specifically designed for use in hazardous environments.

Discover our industrial lighting products ideal for ethanol plants.