2018 Husky Energy Refinery explosion

Last updated
Husky Energy Oil Refinery explosion
Smoke billowing from superior refinery.png
Smoke billowing from the refinery during the fire.
DateApril 26, 2018 (2018-04-26)
Time10:00 AM CST
Location Superior, Wisconsin
Coordinates 46°41′23.9″N92°04′13.4″W / 46.689972°N 92.070389°W / 46.689972; -92.070389
TypeExplosion caused by mixture between flammable hydrocarbons and air.
Deaths0
Non-fatal injuries36

On April 26, 2018, an explosion and subsequent fire occurred at the Husky Energy Oil Refinery in Superior, Wisconsin. An initial explosion was reported at 10:00 AM and was extinguished close to noon, however a piece of debris had hit a storage tank containing asphalt, which ignited after spilling across the refinery, sending a thick plume of black smoke into the air. Thirty-six people, including 11 refinery employees, were sent to local hospitals, but there were ultimately no fatalities. Residents 3 miles to the east and west of the refinery, 2 miles to the north, and 10 miles to the south were evacuated from their homes temporarily due to concerns of both the toxicity of the smoke affecting those who lived south of the refinery and concerns regarding the plant's hydrofluoric acid tank causing further damage. [1] [2]

Contents

Background

The oil refinery in Superior, Wisconsin, which processes 50,000 barrels of oil a day, was acquired by Husky Energy from Calumet Specialty Products Partners in November 2017, retaining 180 Calumet employees. The company processes heavy oil from oil sands and conventional operations in western Canada. The refinery has a partnership with the Superior Fire Department, which provides its personnel training and resources when fighting industrial fires. [3] It was eventually acquired by Canadian company Cenovus Energy in March 2021. [4]

Early morning closure

On the morning of the explosion, at 5:30 a.m., refinery workers were planning to shut down the Fluid Catalytic Cracking Unit (FCCU) of the refinery for routine maintenance. The FCCU is used to break down hydrocarbons from crude oil into smaller hydrocarbons, which can blend into products such as gasoline. When the FCCU is shut down, slide valves in the middle of the unit are used as a barrier between a reactor, containing flammable hydrocarbons, and a regenerator, containing air. If the hydrocarbons and air mix, an explosion can occur. On the morning of the incident, workers attempted to stop the flow of hydrocarbons to the regenerating unit, however, one of the valves was eroded, causing air to flow upward into the reactor, into equipment that contained flammable hydrocarbons. [1]

Explosion and fire

The mix of the air and hydrocarbons caused a massive explosion in the FCCU at approximately 10:00 a.m. that morning. The explosion sent debris flying 200 feet, one piece puncturing a hole in an above-ground storage tank that contained around 50,000 barrels of asphalt, causing the asphalt to spill along the ground into the refinery's main units. The asphalt ignited near additional storage tanks, eventually traveling to the FCCU of the refinery, causing a fire producing thick black smoke to travel into the air. [1] The smoke went so far into the sky, it was picked up on weather radar. [5]

Evacuation

Students wait for rides outside of the school after being evacuated on April 26. Husky energy explosion view from Superior High School.jpg
Students wait for rides outside of the school after being evacuated on April 26.

The black smoke traveled southeast as far as Solon Springs in Douglas County. An evacuation of the plant was ordered at 1:00 p.m., however at 2:41 p.m., an evacuation for residents 10 miles south of the plant was ordered due to concerns of the toxicity of the huge plumes of black smoke. Residents who lived 3 miles north, east, and south of the refinery were also ordered to evacuate due to concerns about the change in the direction of the wind forcing the toxic smoke above more homes, and due to concerns about the refinery's hydrofluoric acid tank causing potential further explosions and damage. Schools in the Superior School District as well as the Essentia Health-St. Mary's Medical Center in Superior was also urged to evacuate. Students were evacuated to an AMSOIL building in northwestern Superior. Schools in the Maple School District in Douglas County were also closed as a precaution. Those injured were taken to hospitals in Duluth, Minnesota. [6] [7]

Firefight

The fire was initially expected to burn for days. The refinery's emergency response team, as well as the Superior Fire Department, initially went defensive against the fire due to concerns of safety due to the intense heat as well as other units of the refinery which were a cause of concern. A plan was developed at around 3 p.m. The large asphalt fire was extinguished with foam, and the fires around the crude unit of the refinery were extinguished with dry chemical fire extinguisher and water. The fire was fully extinguished at 7 p.m., however the evacuation order remained in place until 6 am the next day due to concerns regarding the stability of the plant's hydrogen fluoride tank. [8]

Investigation, lawsuit, and aftermath

A sign on the exterior of the plant counting the days since the plant has been the focus of an incident. Sign at Husky Energy in Superior Wisconsin.jpg
A sign on the exterior of the plant counting the days since the plant has been the focus of an incident.

CSB Investigation

The United States Chemical Safety Board, or USCSB, or CSB, released their final report on the incident on December 29, 2022, saying that the incident "could have been prevented," citing that the debris that was ejected into the air and hit the asphalt tank which caused the fire, could have hit a tank of highly hazardous hydrogen fluoride, since the tank was approximately 150 feet away from the explosion site, 50 feet closer than the damaged asphalt tank. The board also suggested to the Superior refinery to implement safeguards to prevent explosions in the cracking unit and a "slide valve mechanical integrity program that addresses erosion and ensures proper functioning of the slide valves during a shutdown." [9]

Cenovus put out a statement after the report stating that the refinery is cooperating with the CSB to implement their recommendations into the refinery's rebuild, one of them being "new state-of-the-art slide valves in the Fluid Catalytic Cracking unit with enhanced safeguards such as advanced instrumentation to monitor performance in real-time and ensure the operations and engineering staff can carefully assess performance." [10]

Hydrogen-fluoride controversy

Controversy began to rise surrounding the facility's use of HF. Superior Mayor Jim Paine and Duluth Mayor Emily Larson have publicly come forward expressing disapproval with the plant's use of the chemical, citing multiple safety hazards to the surrounding communities had the HF tank been affected by the fire.

Lawsuit

Husky Energy faced a class-action lawsuit against residents who were forced to evacuate their homes, citing a section from the report of the USCSB that stated that their equipment "failed to separate oxygen and hydrocarbons, allowing a flammable mixture to form." [11] Husky reached a $1M settlement in July 2021. [12]

Rebuild

Reconstruction of the refinery began in the fall of 2019, and is expected to become fully operational in early 2023. Construction was halted in May 2020 due to the COVID-19 pandemic, but was resumed in June 2020. [13]

"Husky Friends"

In April 2022, close to the fourth anniversary of the explosion, a group claiming to be a PR firm for Cenovus Energy called "Husky Friends" sent Superior residents postcards and kits containing things such as information about hydrogen fluoride. Cenovus came forward after the group began to announce their campaign to the press saying that they have no ties to the organization. The group's spokesperson told a local news channel in Duluth that the group's intent was to warn people about the dangers of HF using satire. The company has not filed legal action against the firm or announced any plans to. [14]

Related Research Articles

<span class="mw-page-title-main">Oil refinery</span> Facility that processes crude oil

An oil refinery or petroleum refinery is an industrial process plant where petroleum is transformed and refined into products such as gasoline (petrol), diesel fuel, asphalt base, fuel oils, heating oil, kerosene, liquefied petroleum gas and petroleum naphtha. Petrochemical feedstock like ethylene and propylene can also be produced directly by cracking crude oil without the need of using refined products of crude oil such as naphtha. The crude oil feedstock has typically been processed by an oil production plant. There is usually an oil depot at or near an oil refinery for the storage of incoming crude oil feedstock as well as bulk liquid products. In 2020, the total capacity of global refineries for crude oil was about 101.2 million barrels per day.

<span class="mw-page-title-main">Liquefied petroleum gas</span> Fuel for heating, cooking and vehicles

Liquefied petroleum gas, also referred to as liquid petroleum gas, is a fuel gas which contains a flammable mixture of hydrocarbon gases, specifically propane, n-butane and isobutane. It can sometimes contain some propylene, butylene, and isobutene.

<span class="mw-page-title-main">Husky Energy</span> Canadian energy company

Husky Energy Inc. was a Canadian company engaged in hydrocarbon exploration, headquartered in Calgary, Alberta, Canada. It operates in Western and Atlantic Canada, the United States and the Asia Pacific region, with upstream and downstream business segments. In the 2020 Forbes Global 2000, Husky Energy was ranked as the 1443rd-largest public company in the world.

<span class="mw-page-title-main">Texas City refinery explosion</span> 2005 deadly refinery accident

The Texas City refinery explosion occurred on March 23, 2005, when a flammable hydrocarbon vapor cloud ignited and violently exploded at the isomerization process unit of the BP oil refinery in Texas City, Texas, killing 15 workers, injuring 180 others and severely damaging the refinery. All the fatalities were contractors working out of temporary buildings located close to the unit to support turnaround activities. Property loss was $200 million. When including settlements, costs of repairs, deferred production, and fines, the explosion is the world's costliest refinery accident.

<span class="mw-page-title-main">Buncefield fire</span> 2005 oil storage fire and explosion in Hemel Hempstead, England

The Buncefield fire was a major fire at an oil storage facility that started at 06:01 UTC on Sunday 11 December 2005 at the Hertfordshire Oil Storage Terminal, located near the M1 motorway, Hemel Hempstead, in Hertfordshire, England. The terminal was the fifth largest oil-products storage depot in the United Kingdom, with a capacity of about 60 million Imperial gallons of fuel. The terminal is owned by Total UK Limited (60%) and Texaco (40%).

<span class="mw-page-title-main">U.S. Chemical Safety Board</span> Independent U.S. federal agency

The U.S. Chemical Safety and Hazard Investigation Board (USCSB), generally referred to as the Chemical Safety Board (CSB), is an independent U.S. federal agency charged with investigating industrial chemical accidents. Headquartered in Washington, D.C., the agency's board members are appointed by the president and confirmed by the United States Senate. The CSB conducts root cause investigations of chemical accidents at fixed industrial facilities.

<span class="mw-page-title-main">Pembroke Refinery</span>

The Pembroke Refinery is an oil refinery situated on the Pembrokeshire coast in Wales at Rhoscrowther in the community of Angle. It first came on stream in 1964 and was Regent/Texaco's only British refinery. The refinery occupies a prominent position on the south bank of the Milford Haven Waterway and can be seen for many miles. Around a quarter of the site is within the Pembrokeshire Coast National Park which was created in 1952.

<span class="mw-page-title-main">Chevron Richmond Refinery</span>

The Chevron Richmond Refinery is a 2,900-acre (1,200 ha) petroleum refinery in Richmond, California, on San Francisco Bay. It is owned and operated by Chevron Corporation and employs more than 1,200 workers, making it the city's largest employer. The refinery processes approximately 240,000 barrels (38,000 m3) of crude oil a day in the manufacture of petroleum products and other chemicals. The refinery's primary products are motor gasoline, jet fuel, diesel fuel and lubricants.

The Feyzin disaster occurred in a refinery near the town of Feyzin, 10 kilometres south of Lyon, France, on 4 January 1966. An LPG spill occurred when an operator was draining water from a 1,200m³ pressurised propane tank. The resultant cloud of propane vapour spread, until it was ignited by a car on an adjoining road. The pool of propane in the bund caused the storage tank to be engulfed in flames, which produced a Boiling Liquid Expanding Vapour Explosion (BLEVE) when the tank ruptured. This resulted in a fireball which killed and injured firemen and spectators. Flying missiles broke the legs of an adjacent sphere which later BLEVE'd. Three further spheres toppled due to the collapse of support legs which were not adequately fire protected. These vessels ruptured but did not explode. A number of petrol and crude oil tanks also caught fire. The conflagration took 48 hours to bring under control. This incident resulted in the deaths of 18 people, the injury of 81 and extensive damage to the site.

<span class="mw-page-title-main">2009 Cataño oil refinery fire</span> Explosion and fire in Bayamón, Puerto Rico

The 2009 Cataño oil refinery fire, also known as the CAPECO explosion, was a fire that began with an explosion on October 23, 2009, and was extinguished on October 25 at the Caribbean Petroleum Corporation (CAPECO) oil refinery and oil depot in Bayamón, Puerto Rico. While the fire and subsequent explosion occurred close to the city of Cataño, it technically occurred within the borders of Bayamón, even though Cataño was more affected by fumes and evacuation. There were no fatalities, but 3 people were injured.

Cenovus Energy Inc. is a Canadian integrated oil and natural gas company headquartered in Calgary, Alberta. Its offices are located at Brookfield Place, having completed a move from the neighbouring Bow in 2019.

<span class="mw-page-title-main">1975 Philadelphia Gulf refinery fire</span> Fire at refinery in Philadelphia, Pennsylvania

A refinery owned by Gulf Oil Corporation in Philadelphia, located at Girard Point on the Schuylkill River in South Philadelphia, caught fire on Sunday, August 17, 1975. This incident grew into an 11-alarm fire, not brought under control until 24 hours later, and resulted in the death of eight firefighters of the Philadelphia Fire Department (PFD), injuries to 14 other firefighters, and the loss of four PFD vehicles.

The Cenovus Lloydminster Refinery is an asphalt refinery located in the city of Lloydminster, Alberta, Canada owned by Husky Energy. The refinery provides oil products, primarily 30 different grades of asphalt, as well as light distillate, kerosene distillate, atmospheric gas oil, light vacuum gas oil (VGO), and heavy vacuum gas oil. This refinery is Canada's largest asphalt supplier, processing 27,000 barrels of heavy crude oil per day to produce asphalt. Husky is the "largest marketer of paving asphalt in Western Canada with a 29 mbbls/day capacity asphalt refinery located at Lloydminster, Alberta "integrated with the local heavy oil production, transportation and upgrading infrastructure."

<span class="mw-page-title-main">Milford Haven Refinery</span> Former oil refinery in Wales, United Kingdom

Milford Haven Refinery was an oil refinery situated on the Pembrokeshire coast in Wales, United Kingdom. The refinery began operating in 1973 under Amoco's ownership, but in its final years it was owned by Murco Petroleum. The closure of the refinery was announced in November 2014. The site was sold to Puma Energy in 2015 for use as a petroleum storage and distribution terminal.

Western Canadian Select (WCS) is a heavy sour blend of crude oil that is one of North America's largest heavy crude oil streams and, historically, its cheapest. It was established in December 2004 as a new heavy oil stream by EnCana, Canadian Natural Resources, Petro-Canada and Talisman Energy. It is composed mostly of bitumen blended with sweet synthetic and condensate diluents and 21 existing streams of both conventional and unconventional Alberta heavy crude oils at the large Husky Midstream General Partnership terminal in Hardisty, Alberta. Western Canadian Select—the benchmark for heavy, acidic crudes—is one of many petroleum products from the Western Canadian Sedimentary Basin oil sands. Calgary-based Husky Energy, now a subsidiary of Cenovus, had joined the initial four founders in 2015.

<span class="mw-page-title-main">2021 Rockton fire</span>

On June 14, 2021, a maintenance accident at the Chemtool Incorporated manufacturing plant in Rockton, Illinois, triggered a chemical fire that lasted four days and injured two emergency workers. Portions of the village, located north of Rockford near the Illinois-Wisconsin state line, were subject to a mandatory evacuation as a result of the fire. The fire was not contained until June 16, with the evacuations lasting until June 18.

An explosion at the ARCO Chemical (ACC) Channelview, Texas petrochemical plant killed 17 people and injured five others on July 5, 1990. It was one of the deadliest industrial disasters in the history of the Greater Houston area.

<span class="mw-page-title-main">2019 Philadelphia refinery explosion</span> Hydrofluoric acid spill and industrial fire

In the early morning of June 21, 2019, a fire and multiple explosions occurred at the Philadelphia Energy Solutions (PES) refinery in Philadelphia, Pennsylvania. A release of hydrocarbons and hydrofluoric acid in the refinery's alkylation unit caused a ground-hugging vapor cloud which rapidly ignited, leading to three separate explosions minutes apart from each other. The largest explosion, a BLEVE, sent a vessel fragment flying 2,000 feet (610 m) across the Schuylkill River. Five employees sustained minor injuries, but there were ultimately no fatalities. The refinery announced it would shut down operations the same month, and filed for bankruptcy a month later.

The Beacon Oil explosion occurred on February 10, 1928, at the company's distilling plant in Everett, Massachusetts. 14 people were killed in 36 injured in the disaster.

References

  1. 1 2 3 Factual Investigation Update, April 26, 2018 Husky Superior Refinery Explosion and Fire
  2. Derosier, Alex (April 26, 2018). "Explosion rocks Wisconsin refinery, injuring at least 11, forcing evacuations". CBS News . Retrieved January 30, 2022.
  3. "Husky Energy to buy $435 million Wisconsin refinery". Reuters . August 14, 2017. Retrieved January 30, 2022.
  4. Maria Shibu, Ann; Nickel, Rod (October 25, 2020). "Canada's Cenovus to buy Husky for $2.9 billion as pandemic drives oil mergers". Reuters . Retrieved July 23, 2022.
  5. "Smoke from Wisconsin oil refinery explosion shows up on radar". KMSP-TV . April 27, 2018. Retrieved January 30, 2022.
  6. Forliti, Amy; Baenen, Jeff (April 26, 2018). "Smoky fire that forced evacuations out at Wisconsin refinery". Associated Press . Retrieved January 30, 2022.
  7. Jones, Meg (April 26, 2018). "At least 20 reported injured in Wisconsin oil refinery explosion, followed by more blasts and fires". KARE 11 . Retrieved January 30, 2022.
  8. Reinan, John; McKinney, Matt (April 27, 2018). "Superior, Wis., evacuation order lifted at 6 a.m., mayor says". StarTribune . Retrieved January 30, 2022.
  9. "FCC Unit Explosion and Asphalt Fire at Husky Superior Refinery - No. 2018-02-I-WI" (PDF). U.S. Chemical Safety Board : 195. December 23, 2022.
  10. McConico, Matt (December 29, 2022). "Husky Superior Refinery explosion report released". Northern News Now . Retrieved December 30, 2022.
  11. Raguse, Lou; Haavik, Emily (September 5, 2018). "Lawsuit filed against Husky Energy, Superior Refining". KARE 11 . Retrieved January 30, 2022.
  12. Johnson, Brooks (July 12, 2021). "Superior refinery reaches $1M settlement, will pay residents who evacuated". StarTribune . Retrieved January 30, 2022.
  13. "Superior Refinery Rebuild". Husky Energy . Archived from the original on 2018-05-29. Retrieved January 30, 2022.
  14. Milles, Larissa (April 26, 2022). "Husky Hoax: Activists pretending to work for refinery reach out to Superior residents". Northern News Now . Retrieved September 12, 2022.