A Brief Guide to Lithium-ion Battery Fires

Causes

Lithium-ion batteries power many devices, but they can pose serious fire safety risks under certain conditions. Fire safety is essential when handling these batteries, as fires can result from physical damage, overheating, or manufacturing defects. Understanding these causes is key to preventing accidents at work, home, or during transport.

This is especially true and relevant today, as lithium-ion battery fires are increasing in frequency the more it is utilized in modern devices and daily items. In the UK, discarded lithium-ion batteries are considered responsible for an estimate of at least 200 fires a year as of 2023. Meanwhile, in the US, New York City reports having experienced a minimum of 12 deaths and over 250 injuries related to lithium-ion battery fires from 2021 to 2023 alone.

Here are some of the main causes of these fires as per the US National Fire Protection Association (NFPA):

• Physical damage: Impacts or punctures done to the battery or the surrounding casing can break internal components and cause short circuits.
• Overcharging or overheating: Excess heat or excessive voltage can trigger thermal runaway.
• Manufacturing defects: Design flaws or contamination during production can lead to internal failures.
• Improper storage or handling:  Storage conditions where batteries are held in extreme temperatures, near metal objects, or poorly ventilated areas can increase the risk of short circuits or thermal runaway.
• Battery age and wear: Over time, lithium-ion batteries’ performance degrades, and as they age, they are more likely to experience internal faults, making them more susceptible to fires.

Risks

Lithium-ion battery fires are a major concern for many organizations, as they pose various risks to workers and facilities. However, these batteries are also essential for various everyday tasks, which is why it’s crucial for teams to understand and mitigate the risks that come with these batteries.

Some of the major risks that come with lithium-ion battery fires are the following:

• Property damage: Fires can destroy equipment, inventory, and infrastructure, leading to costly repairs or replacements.
• Business interruptions: Sudden lithium-ion batteries exploding or malfunctioning can lead to fires that may cause operational downtime, delays in production, and disruptions to services or deliveries.
• Legal liabilities: Companies could face lawsuits or regulatory fines if found negligent in handling or storing lithium-ion batteries improperly.
• Reputational damage: Incidents can harm a business’s reputation, leading to loss of customers or trust.
• Employee safety risks: Following lithium-ion battery fires, employees may suffer injuries from fires, smoke inhalation, or explosions, resulting in potential workers’ compensation claims and loss of workforce productivity.
• Environmental impact: Fires may release toxic fumes or chemicals, causing environmental damage and requiring expensive clean-up efforts.

How To Improve Lithium-ion Battery Safety

Organizations that use devices with lithium-ion batteries must pay close attention to battery safety. This is done to prevent fires and also to improve the overall safety of the workplace. Here are some ways teams can improve lithium-ion battery safety within the organization:

Efficient Training

Providing thorough training for employees on the safe handling, storage, and charging of lithium-ion batteries is essential to preventing accidents. Regular safety courses can help raise awareness about the potential risks and proper safety procedures. Well-trained personnel can identify hazards early, perform the necessary risk assessments, and take preventive measures to avoid fires.

Regular Inspections

Conducting regular inspections of lithium-ion batteries can identify signs of wear, damage, or potential malfunctions before they lead to dangerous situations. Inspections help ensure that batteries are in good condition and being used safely, as well as identify the need for maintenance. With a digital inspection form in particular, it becomes easier to conduct checks on lithium-ion battery-powered items, anytime and anywhere. Addressing issues promptly can prevent accidents and extend the lifespan of the batteries.

Proper Storage

It’s essential to store  lithium-ion batteries and their casings in cool, dry environments, away from flammable materials, as doing so reduces the risk of overheating or fire. Proper storage involves using approved containers and ensuring batteries are not exposed to extreme temperatures or physical damage. This helps minimize the likelihood of thermal runaway and other electrical or fire issues.

Strict Charging Protocols

Implementing strict charging protocols, such as using manufacturer-approved chargers and never overcharging batteries, helps prevent overheating and potential fires. Monitoring battery voltage and temperature during charging can also reduce the risk. Adhering to these guidelines ensures that batteries are charged safely and efficiently.

Create an Emergency Response Plan

Combined with efficient training, having a well-defined emergency response plan for battery-related incidents ensures that businesses can react quickly and effectively if a fire occurs. This plan should include evacuation procedures, fire suppression methods, and communication protocols. Regular drills and clear instructions can minimize damage and injury in the event of an emergency.

Role of Technology in Safe Battery Fire Management

Modern technology has significantly improved lithium-ion battery safety by providing advanced tools for monitoring and managing batteries. These innovations help detect potential risks early, ensuring better prevention and response to safety issues. As a result, businesses can maintain safer environments while extending the lifespan of their batteries. Here are some ways technology can improve overall battery safety and usage:

• Digital checklists:  Digital fire safety checklists and lithium-ion battery inspection checklists ensure a consistent and systematic approach to safety checks, reducing human error and ensuring all necessary steps are completed. These help users flag issues in real time, enabling quick corrective actions to prevent potential risks.
• Smart sensors:   Smart sensors today can be linked to digital solutions and cloud storage, helping monitor critical battery parameters like temperature, voltage, and charge levels, providing real-time data for early detection of abnormalities. These sensors also alert operators to any dangerous conditions, allowing for immediate intervention before a fire or failure occurs.
• Asset management tools:  QR codes and other asset tags can now link batteries to digital profiles containing their usage and maintenance history, making it easy to track their condition. This helps ensure batteries are properly maintained and replaced as needed, reducing the risk of accidents caused by aging or faulty batteries.