It is the only structure of its kind in operation in Brazil. Housed in the Triunfo Petrochemical Complex in the state of Rio Grande do Sul, the Braskem Fire-Fighting Training Center has a specific area for fire tests of passenger car fuel tanks made with a special type of plastic that Braskem supplies to the auto industry.

The tests meet this country’s official technical requirements and are performed with the use of a large container, which is ignited during testing, and a crane, which lifts the car to be exposed to the flames. The area is cordoned off with concrete walls, and fire-proof glass windows protect the people monitoring the test at a minimum distance of three meters. During the trials, the fuel tank is attached to the vehicle and filled to 50% capacity.

After one minute, the burning container is moved using a mat, and placed under the fuel tank, which is directly exposed to the fire for 60 seconds. Then, a brick screen is placed between the flames and the tank for another minute. Finally, the container is removed and firefighters extinguish the flames. “This test has to be carried out on every car model using at least three tanks, so the product is technically approved without having any sort of leak,” says Marcos Celestino, the Braskem application engineer who oversees all tests performed at the company.

The last test was conducted in April on the tank of a new model that will hit the market in September 2010. The product was manufactured by IPA, South America’s leading manufacturer of plastic fuel tanks. IPA became a Braskem client two years ago. During that period, the two companies have already partnered up to conduct other fire tests for tanks used in the Honda Fit, Honda Civic and Citroën Crosshair, explains Luiz Cláudio Pascon, Industrial Director of IPA. He stresses the importance of maintaining a close relationship with Braskem. “We must always seek joint solutions to make adjustments and innovations,” he says.

According to Harley Bueno, a Director of the Brazilian Automotive Engineering Association (AEA), automakers are increasingly concerned about the safety of their vehicles, and preventing fuel tank leaks is essential. Therefore, they are subjected to pressure, thermal and leak tests, in which their efficiency is also determined by applying force.

“Safety, space and design are the most important factors for clients in the automotive market”Marcos Celestino

The advantages of plastic as raw material for fuel tanks have led to that application’s rapid growth in recent years. “The properties of polyethylene make it more resilient and ensure greater impact absorption compared to metal,” observes Marcos Celestino. “Safety, space and design are the most important factors for clients in the automotive market. The properties of plastics cover all these requirements,” he says. Harley Bueno stresses the malleability of the raw material as an asset. “Plastic tanks can fit in ever-smaller spaces without interfering with the vehicle’s autonomy. For example, a fuel tank installed under the seat is less likely to be damaged in an accident than if it is at one end of the vehicle,” he explains.

Braskem is the leading supplier of plastic resins used to make light and heavy vehicles in South America. For that market, the company produces a family of special High Molar Mass High-Density Polyethylene products (coded as GM 7746 C and GM 7746 CA).

Ressoi Schubert, Braskem’s Account Manager for Performance Products, notes that 66% of the passenger cars made in Brazil in 2009 were equipped with plastic tanks. “The expectation is that this percentage will reach 74% in two years,” she says. One hundred percent of vehicles made by manufacturers like Honda, Toyota, Renault and Peugeot already use plastic tanks; the figure for GM is 95%, and for Volkswagen and Ford, 85%.