Lithium Battery Fire Prevention

Over the past decade, lithium-ion (Li-ion) batteries have become an integral part of our daily lives. Despite their widespread use, our understanding of the risks associated with this technology has not kept pace. These batteries were introduced with little fanfare or instruction, often built into devices where the focus was on the device itself rather than its components.

Early Warning Signs

The first major warning signs for the general public came in the summer of 2016, with reports of cell phones exploding. Even more concerning were the incidents involving the Dreamliner aircraft fleet three years earlier, which had to be grounded due to several ‘thermal runaway’ events. The subsequent NTSB investigation highlighted that the FAA did not recognize the potential for cascading thermal runaway due to a cell internal short circuit. More recently, the FDNY has been addressing a series of fatal fires linked to lithium-ion batteries from personal mobility devices.

The Problem with Li-ion Batteries

Li-ion batteries can fail in a chain reaction known as “thermal runaway.” During thermal runaway, the battery self-heats, building pressure until it bursts and releases toxic and flammable gases. This can trigger secondary reactions, potentially resulting in explosions or fires. Damaged or misused batteries are the primary causes of thermal runaway. Factors such as punctures, cracks, high heat exposure, overcharging, or manufacturing flaws can all lead to this dangerous condition.

Key Points to Know

• Thermal Runaway: Damaged Li-ion batteries present an increased chance of thermal runaway, which can occur immediately or even weeks after damage.
• Dead Batteries: A ‘dead’ battery is not necessarily safe. An early sign of thermal runaway is a sudden drop in battery voltage to zero.
• Off-gassing: Both working and dead batteries can off-gas toxic and flammable substances. Larger batteries, like those in tools or scooters, can fill a room with these gases.

Best Practices for Li-ion Battery Safety

1. Use Original Manufacturer Batteries: Off-brand batteries are frequently associated with incidents. Major manufacturers often reject a significant percentage of battery cells as flawed.
2. Temperature Protection: Keep batteries out of direct sunlight and water. Do not charge below 32°F or above 105°F.
3. Regular Inspections: Check for punctures, cracks, deformities, swelling, discoloration, corrosion, leaking, venting, or intense heat.
4. Handling Damaged Batteries:
   • Remove from service immediately.
   • If off-gassing in an enclosed space, evacuate and contact the Fire Department.
   • Place damaged batteries in nonflammable containers with sand or vermiculite.
   • Contact a HAZMAT disposal vendor or commercial battery recycler for proper disposal.
   • Never dispose of Li-ion batteries in regular trash or recycling bins.

Additional Resources

For more detailed information, you can refer to the following resources:

• PTI Power Tool Institute  https://www.takechargeofyourbattery.com/
• DOT Understanding the Risks of Damaged, Defective, or Recalled (DDR) Lithium Batteries https://hazmat.dot.gov/sites/phmsa.dot.gov/files/2023-03/final.pdf
• Guide to Performance Packaging Codes
• FEMA Battery Fire Safety

By understanding these risks and following best practices, we can safely manage the use of lithium-ion batteries in our daily lives.

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Author:  Alistair Paget, CSP, eGage Safety & HR Consulting