Ethanol production has become an essential industry in the U.S., where millions of tons of grain, primarily corn, are processed to create biofuel. While ethanol plants contribute significantly to renewable energy, these facilities also expose workers to numerous hazards, particularly during the grain handling process.
From potential dust explosions to crushing injuries, the risks associated with ethanol plant equipment are significant. Workers in these plants deserve to understand the hazards they face, know the common causes of incidents, and be equipped with the knowledge needed to protect their legal rights if they are injured. That is why the work injury attorneys at Kherkher Garcia have compiled the guide below. As always, workers with questions can contact us by calling 713-333-1030.
Recent Explosion Damages Grain Handling Equipment
Aurora, Nebraska firefighters responded to a grain dust explosion at the KAAPA ethanol plant in Aurora West earlier this week. The explosion occurred around 8:45 p.m. on the grain elevator side, causing significant structural damage to grain handling equipment. Firefighters extinguished a small fire in dust collection equipment on arrival. Since the corn transfer operation was conducted remotely, no one was in the immediate area, and there were no injuries.
The fire department deployed 15 firefighters, including an ambulance crew, as a precaution. The State Fire Marshal’s office was notified, and inspectors, including a grain fire specialist, were on site. The explosion was attributed to a bearing failure in a grain leg. While the blast was loud enough to shake nearby homes, it did not significantly disrupt plant operations, as farm trucks continued delivering grain the following morning.
Incidents like this one serve as a reminder of the type of incidents that can occur in ethanol plants.
Understanding Grain Handling Equipment in Ethanol Plants
Grain handling in ethanol plants involves various stages, from receiving raw grain and drying it to milling, fermentation, and distillation. This process requires specialized equipment, including conveyors, grain elevators, dryers, silos, and grinders, which move, process, and store grain through the different production stages. However, as crucial as this equipment is for ethanol production, it can pose severe risks to workers’ safety. The movement of large quantities of grain can result in hazards such as dust explosions, entrapment, and exposure to toxic substances.
Hazards Associated with Grain Handling Equipment in Ethanol Plants
Dust Explosions
Grain dust is highly combustible and can ignite when it accumulates in certain conditions. When dust particles in the air are exposed to a spark or heat source, they can ignite, causing a potentially devastating explosion. The risk of explosion is especially high in confined spaces, such as silos and hoppers, where dust can accumulate in high concentrations. Ethanol plants are particularly vulnerable to dust explosions because the dry grain dust can easily become airborne and ignite.
Primary and secondary explosions are common in these settings. A primary explosion occurs at the initial ignition point, while a secondary explosion follows as the initial blast disperses more dust, triggering further ignition and potentially catastrophic outcomes.
Crushing and Amputation Injuries
Ethanol plants rely on conveyors and grain elevators to transport materials throughout the production process. These machines have moving parts that pose severe crushing and amputation risks to workers. Grain augers and conveyors are particularly hazardous because they use rotating components to move grain. Workers who come into contact with these parts, either directly or through loose clothing or jewelry, may suffer severe injuries.
Equipment malfunctions, lack of proper guarding, and inadequate safety protocols can contribute to these incidents, which can lead to life-altering injuries.
Entrapment and Suffocation
Grain silos, hoppers, and storage bins pose entrapment and suffocation hazards. When a worker enters a confined space filled with grain, they risk becoming engulfed if the grain shifts or they slip, potentially leading to suffocation. In many cases, workers may become entrapped during maintenance or cleaning, where they may be required to enter silos or bins without adequate protection or support systems.
Grain flow can also trap workers when it begins to move unexpectedly, creating a “quicksand” effect that rapidly engulfs them. Entrapment incidents in grain facilities are often fatal due to the rapid nature of grain engulfment.
Toxic Fumes and Hazardous Chemical Exposure
The fermentation and distillation processes in ethanol production can release hazardous gases, including carbon dioxide, ethanol vapors, and hydrogen sulfide, which can cause respiratory issues, unconsciousness, or even death if inhaled in high concentrations. Workers may also come into contact with other hazardous chemicals, such as solvents and disinfectants, used during cleaning and maintenance processes. Prolonged exposure to these chemicals without adequate ventilation or personal protective equipment (PPE) can cause serious health problems, including respiratory issues and chemical burns.
Noise-Induced Hearing Loss
Ethanol plants are typically noisy environments due to the operation of heavy machinery, grain dryers, and conveyors. Prolonged exposure to high decibel levels can cause hearing loss in workers. Although hearing protection is often required, inadequate or improperly used protection can lead to irreversible hearing damage, affecting a worker’s quality of life and employability.
Fires and Burns
Ethanol production involves processing flammable substances, which creates a high fire risk. Equipment such as grain dryers and storage tanks containing ethanol can ignite if safety protocols aren’t followed. Workers are also at risk of burns from hot surfaces, steam, and accidental fires that can ignite around ethanol vapors. Fire incidents in these facilities can quickly escalate, putting workers’ lives in jeopardy.
Common Causes of Incidents and Injuries in Ethanol Plants
Incidents and injuries in ethanol plants may occur for a variety of reasons. Some of the common factors that contribute to injuries include:
Lack of Proper Training
In many cases, incidents occur due to a lack of adequate training for workers on the hazards of grain handling equipment. Without the necessary knowledge, workers may not understand the risks or may engage in unsafe practices around high-risk equipment.
Inadequate Safety Procedures
Ethanol plants are required to follow strict safety procedures to prevent accidents. However, some facilities may fail to implement or enforce adequate safety protocols, leading to avoidable accidents. Common safety oversights include failing to regularly clean areas prone to dust accumulation, improper equipment maintenance, and lack of proper shutdown procedures during equipment maintenance.
Inadequate Safety Guards on Equipment
Machinery like augers and conveyors should be equipped with guards to protect workers from direct contact with moving parts. Unfortunately, missing or defective guards are a significant factor in many crushing and amputation injuries.
Poor Ventilation and Lack of PPE
Ethanol plants should ensure adequate ventilation to reduce dust concentration and protect workers from toxic fumes. When plants lack proper ventilation or fail to provide PPE, workers are left vulnerable to respiratory issues, chemical burns, and dust explosions.
Neglecting Lockout/Tagout Procedures
Lockout/tagout (LOTO) procedures are critical to preventing unexpected equipment startup during maintenance or repairs. Failing to implement these procedures can result in severe injuries, including crushing or amputation.
Delayed or Inadequate Emergency Response
In the event of a fire, explosion, or entrapment incident, a delayed response can exacerbate injuries or lead to fatalities. Ethanol plants must have clear and regularly practiced emergency response plans to reduce harm during an emergency.
How Workers Can Protect Their Legal Rights After an Injury
Workers in ethanol plants undoubtedly know that there are hazards to these work environments. So, how can workers protect their legal rights and seek help if they are injured on the job? Consider the following:
Report the Injury Immediately
It is essential for injured workers to report the incident to their employer as soon as possible. Reporting documents the incident and ensures that it is officially recorded, which can be critical evidence if the worker decides to pursue legal action.
Seek Medical Attention
After any workplace injury, workers should seek immediate medical treatment, even if the injury seems minor. A medical report will provide documentation of the injury’s extent, which can support the worker’s claim.
File a Workers’ Compensation Claim
Most ethanol plant workers are eligible for workers’ compensation, which provides benefits for medical expenses, lost wages, and disability. Workers should follow their employer’s procedures for filing a workers’ compensation claim.
Document Everything
Workers should keep records of all documents related to their injury, including medical bills, treatment records, communication with the employer, and witness statements. Documentation will support a workers’ compensation claim or any additional legal action.
Consult with an Experienced Attorney
Workers injured in ethanol plants may have grounds for a personal injury or third-party liability claim, particularly if the injury resulted from unsafe equipment, negligence, or failure to follow safety protocols. A skilled attorney can assess the case, gather evidence, and represent the worker’s best interests in court.
Attorneys can also investigate whether safety regulations were violated, including OSHA standards, to determine if there is additional liability beyond workers’ compensation.
Understand Your Rights
Workers have the right to a safe work environment under the Occupational Safety and Health Administration (OSHA) regulations. If safety violations contributed to an injury, workers might have grounds for an OSHA complaint or a lawsuit against their employer.
Getting Help After an Ethanol Plant Work Injury
Ethanol plants play a pivotal role in energy production but are fraught with hazards that can put workers at significant risk. From dust explosions and crushing incidents to toxic fume exposure, workers in these plants face a wide array of potential dangers. While some risks are inherent to the industry, employers have a duty to minimize hazards and protect their employees through training, proper equipment maintenance, and adherence to safety protocols.
If you or a loved one has been injured while working at an ethanol plant, it is crucial to take steps to protect your legal rights. Consulting with an experienced attorney can be invaluable, helping you navigate the workers’ compensation process and determine if you have grounds for a personal injury claim.
At Kherkher Garcia, our team of work injury attorneys is dedicated to helping injured workers secure the compensation they deserve. Contact us today for a free consultation to understand your options and start the journey toward recovery. Call us at 713-333-1030, or complete our website contact form to get started.
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