Dow Plant Fire in Freeport Released 2+ Tons of Chemicals, Company Reports

FREEPORT — A fire broke out Monday night at Dow Chemical’s Plant B along N. Brazosport Boulevard, triggering more than two tons of chemical emissions, according to a report filed with the Texas Commission on Environmental Quality (TCEQ). The blaze has raised fresh concerns about industrial safety, air quality, and transparency in chemical plant operations.

Dow officials described the incident as an “unexpected facility upset,” confined to one unit within Plant B, which was contained within about four hours, with no injuries reported. The emissions began at 7:03 p.m. and were projected to continue until Wednesday night unless processing conditions stabilized.

According to the emissions report, Dow estimated that at least 1,553 pounds of ethylene, 1,140 pounds of octene, 892 pounds of 2-hexene, 434 pounds of carbon monoxide, 378 pounds of octane, and 217 pounds of nitrogen oxide were released. About half of those emissions escaped from piping in temperature-controlled units used to convert ethylene into plastics.

Dow also reported that a “flare outage” occurred—a failure in the system that safely burns off excess gases, which serves as a backup to prevent more dangerous releases. The company blamed the flare outage for part of the escape of emissions.

Residents across Freeport and nearby areas posted images and videos of towering flames and dark plumes of smoke on social media, with many describing the spectacle as “huge” and “alarming.”

While emissions were significant, the company and regulators say no injuries or adverse effects have been confirmed so far. The fire triggered visible safety concerns and now places pressure on both Dow and the state to clarify how such incidents will be prevented in the future.

The incident underscores questions about the reliability of safety systems in large chemical facilities, especially when a backup (flare) fails simultaneously with a primary failure. It also brings to light concerns over public notice: in the recent chlorine leak in Brazoria County, many residents reported failing to hear sirens or official alerts.

The TCEQ will review Dow’s emissions report and investigate whether the company complied with relevant permit limits and notification requirements. Local activists and environmental groups are calling for more public transparency, real-time release data, and closer scrutiny of Dow’s safety protocols.

As the official review proceeds, the community will be watching whether this fire becomes a case study in how industrial releases are managed—or mishandled— in heavily industrialized zones like Freeport.

TL;DR

A fire at Dow’s Plant B in Freeport released more than two tons of chemicals — including ethylene, octene, and carbon monoxide. The blaze was contained in about four hours, with no confirmed injuries, but revealed a flare backup system outage and reignited concerns about industrial safety, emissions transparency, and public risk.