Lithium ion batteries gained notoriety after cases of smartphones catching fire made headlines in 2017. Although lithium ion batteries can be very safe, they require precise engineering and special safety precautions to prevent fires.
The best method for dealing with lithium ion battery fires is to prevent them from happening in the first place. This is why shipping companies require lithium battery shipping boxes and other protective measures for any shipment containing batteries.
Lithium Battery Shipping Boxes Help Prevent Fires Before They HappenOnce a fire has started, the race is on to put it out. Lithium ion battery fires are even more dangerous than fires from older batteries because they release a flammable vapor that is toxic and which essentially produces its own fuel.
Strategies for putting out a lithium ion battery fire vary depending on the fire’s location and size. However, as a general rule, special fire suppressants are required for the fire to be fully and safely extinguished.
But first, here are four things you should know about lithium ion batteries:
- Lithium ion batteries are a Class B flammable liquid and require dry chemical extinguishers to put out.
- It is vital to implement the appropriate preventative measure to avoid a chemical reaction that could start a fire.
- Facilities that store or transport lithium batteries should be outfitted with a fire suppression system or have protocols in place to extinguish fires quickly.
- During shipping, especially via plane or ship, lithium batteries need protective packaging and the correct HAZMAT labels.
Basics of Lithium-Ion Battery Fires
Lithium ion battery fires usually occur after a battery has been damaged. Damage to a battery can cause a rupture in the membrane that separates the chemicals inside, causing a reaction that sparks a dangerous and self-perpetuating fire. Although these fires were poorly understood at first, analyses show a thermal runaway causes fire and explosion of the lithium ion batteries.
In any environment, small lithium ion fires can be put out with special fire extinguishers. Contrary to popular belief, Class D fire extinguishers are ineffective on lithium ion fires. Although they are labeled for use on metal fires, lithium ion batteries are a special case because they do not contain any actual lithium metal. The dry powder in Class D fire extinguishers will not slow a lithium ion chemical reaction.
Lithium ion battery fires are considered a Class B flammable liquid fire. A type ABC or BC fire extinguisher is effective against this type of blaze. These fire extinguishers interrupt the chemical reaction in the lithium ion battery, eventually stopping the fire.
Fire extinguishers designed to combat Class B fires are available in a few different formats. The best one is the dry chemical type because the extinguisher can launch the dry powder up to 20 feet horizontally. Carbon dioxide (CO2) and foam fire retardants are also effective, but their range is around half that of dry chemical extinguishers. Clean agent extinguishers are better for the environment and are less harmful to humans, so they are a better choice for close quarters like airplanes.
Surprisingly, water can be somewhat effective in dampening lithium ion fires, in part because it reduces the heat. However, chemical fire retardants are more effective, and any industrial or transportation setting that regularly has lithium ion batteries present should invest in more substantial fire prevention systems and protocols.
Preventing the Fire from Spreading
Ideally, the storage area containing the battery will have appropriate safeguards in place to prevent the fire from spreading too quickly. This includes metal fire doors between different types of flammable objects and an overhead fire suppression system.
Hazmat Shipping Labels Ensure Lithium Ion Batteries Are Well ProtectedIn case of a fire, ventilation systems should also shut down to prevent the spread of smoke and avoid fueling the fire with fresh oxygen. Although it is possible to do this manually, it should ideally happen automatically so staff can focus on evacuating.
Instead of eventually running out of fuel and extinguishing itself, a lithium ion battery fire may self-perpetuate and reach extremely high temperatures even in a closed environment. So, while preventing the fire from spreading is an essential first step, it is insufficient for putting the fire out. The property owner must be prepared to tackle the fire head-on with a chemical fire extinguisher.
Considerations for Warehouses
Warehouses can invest in advanced fire suppression systems that drop fire retardants from overhead. These systems typically use foam instead of dry chemical powder. The best option for your warehouse may vary depending on the types of products you store, the ceilings’ height and the storage and racking density.
The exact fire prevention requirements for a warehouse also vary depending on local fire codes and the exact types of hazardous and flammable materials in storage. Even if lithium ion batteries are the only flammable item held there, warehouses will need hazmat labels to identify the products and indicate the best way to store and protect them.
Warehouses must take care to separate flammable materials from one another as much as possible. This prevents fires from snowballing so fast they become impossible to extinguish. The heat from other burning materials can cause lithium ion batteries to catch fire easily, even if the battery is in good condition.
Putting Out Fires on Airplanes
Airplane cargo holds have built-in fire suppression systems designed to automatically trigger when they detect high heat levels. These systems also notify the pilot a fire has been detected so they can take immediate action to land the plane. Once the aircraft is on the ground, specialized fire trucks can insert long sprayers into the cargo hold to thoroughly coat the inside with a fire retardant.
Aircraft crew members are also carefully trained on how to use fire extinguishers to extinguish fires from passengers’ cell phones or laptops. Although there are small fireproof bags crews can use to put out fires, the FAA has discouraged crews from using these bags with lithium ion batteries. Some of these bags cannot completely contain the smoke generated by the batteries, and trapping the battery’s heat inside a bag can actually make the chemical reactions worse.
Because of the chance of a catastrophic accident due to a cargo hold or cabin fire, the FAA and other governing bodies have continuously updated their regulations on using or sending lithium ion batteries via airplane. Lithium ion batteries are currently banned from being shipped in the cargo hold of a passenger aircraft but may still be shipped via cargo plane.
Fire Suppression on Cargo Ships
Airplanes have unique concerns regarding lithium ion batteries, but cargo ships must be mindful of them as well. Despite attempts to improve fire prevention regulations, catastrophic fires onboard cargo ships have destroyed millions of dollars’ worth of property in the past few decades.
Fire suppression on cargo ships typically uses either water or CO₂ sprayed from above, much like a warehouse would. The International Maritime Organization’s requirements for cargo ships aren’t as strict as those of passenger ships, but they are still thorough. However, even an IMO-compliant fire prevention strategy may be insufficient in cases where the cargo holds have few or no fire doors to contain a fast-burning fire.
Like with airplanes, cargo ships require hazmat shipping labels for lithium ion batteries. There is also usually export and import paperwork required for sea shipments, and this paperwork should indicate that lithium ion batteries are onboard.
There is a rising problem of incorrectly declared or labeled shipments, especially as importers try to skirt tariffs. If a shipment contains lithium ion batteries and it is unknowingly stored too close to other hazardous goods, the resulting fire may be catastrophic. As cargo ships develop new ways of separating dangerous goods, these labels could make the difference between life or death for sailors.
The Benefits of Professional Systems
You or your employees can put out a small lithium ion battery fire with enough water or with the right type of fire extinguisher if you notice the fire right away. However, fires can grow very fast before they are caught, especially if some of the initial smoke is contained by a cardboard box or shipping container. In an unoccupied room with high ceilings, it may be several minutes before a smoke detector notices the fire.
Even if an employee notices the fire right away, handheld fire extinguishers are vulnerable to user error. Also, the smoke from lithium ion battery fires irritates the mucus membranes in your throat and nose and is also carcinogenic. Anyone who has to spend more than a few seconds putting out the fire is at risk of severe lung irritation.
While the fireproof bags used on airplanes sometimes work for battery fires, they require the user to pick up the battery with fireproof gloves. This requires the user to come close to the burning battery, which increases the risk of burns and harmful smoke inhalation.
In other words, handheld fire suppression systems and improvised tactics are not an ideal option. If you regularly store or transport lithium ion batteries, then relying on small handheld fire extinguishers is a risk you just can’t take. Invest in an extensive built-in fire suppression system in coordination with fire safety professionals to maximize your facility’s safety.
Essential Prevention Methods
Regardless of the mode of transportation or storage location, there are a few common elements to preventing lithium ion battery fires from starting in the first place. For manufacturers, the most significant aspects are preventing the batteries from overheating and using careful quality control to keep defective batteries from leaving the factory.
Generally, this issue is out of the hands of distributors and other outside parties. However, you can do your part to prevent fires in these cases by paying close attention to all recall information coming from the companies you work with or government agencies.
For consumers and distributors, the biggest potential cause of battery fires is damage to the battery. The permeable membrane separating chemicals inside the battery is designed to absorb minor bumps, but it will not tolerate severe damage during the shipping process. It is best treated with the same care as a fragile or hazardous item.
Hazmat Requirements
Most consumer-model lithium ion batteries technically are not considered Hazmat if they are under 100Wh. However, shipments of multiple batteries may fall under Hazmat and require hazmat shipping labels. Even non-Hazmat batteries should have a caution sticker on the outside to encourage safe handling.
If shipping two or more batteries over 100Wh or eight or more batteries over 20Wh, distributors and warehouse owners must adhere to Hazmat Class 9 rules for miscellaneous hazardous items. This means lithium ion batteries are considered a hazard during transportation but are not typically a hazard when in a stable location. While you are not required to use special storage requirements while the batteries are not in transit, it’s wise to keep them clearly marked so people know to handle them with caution.
Once your batteries are on the move, it’s vital to keep them well padded. And how else to do that than vermiculite? If you’re asking: “What is vermiculite used for?,” check out our guide! You can also consider using bubble wrap, eco-friendly packing foam and other traditional packaging.
Lithium ion batteries also need careful external packaging even when it’s not strictly required by Hazmat regulations. Custom size cardboard boxes are ideal for packing batteries securely so they don’t sustain damage in transit. Hazmat-approved boxes must have a certain amount of crush resistance as well, depending on contents and the mode of transportation.
When palletizing lithium ion batteries, keep in mind, carriers may have additional requirements for the maximum total number of batteries that can be sent at one time. Double-check your carrier’s requirements for specific modes of transportation and routes. International routes are more likely to have additional rules and restrictions.
Maximizing Safety
Battery technology is an ever-evolving field, and best practices for preventing fires may continue to evolve as well. Consumers are always eager to get bigger and better batteries, but the chemical reactions involved in batteries mean these products are susceptible to damage from heat and physical stress.
Unfortunately, putting out lithium ion battery fires will continue to be a challenge even as their overall safety improves. Although standard BC and ABC fire extinguishers work, they are hard to use effectively once the fire has spread. If an entire pallet of lithium ion batteries is on fire, it’s likely that just one fire extinguisher will be insufficient.
Warehouse owners and transportation companies often have unique fire suppression needs, and professional assistance for fire suppression strategies is wise. As a general rule, lithium ion fires are not difficult to put out if they are spotted right away. The danger arises when they grow and reach other flammable and dangerous goods stored in the same area.
The best course of action is to be prepared for potential fires and to also prevent them. Crush-resistant boxes, padding and awareness of defective and recalled goods can help you dramatically reduce the risk of fires. By being proactive, you can enhance the safety of your entire team while avoiding catastrophic losses.
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