Understanding Lithium Battery Safety

Lithium- batteries have become an integral part of our daily lives both at home and within the workplace, powering everything from smartphones and laptops to electric vehicles including cars, bikes and scooters and renewable energy storage systems. Offering benefits like low maintenance, long lifespans, fast charging, and unlimited cycle life, lithium-ion batteries have become ubiquitous in consumer electronics.

Despite their benefits, lithium-ion batteries pose a risk and there have been numerous reports and studies published on the negative impacts of such batteries.

London Fire Brigade recently published a report after two homes were destroyed in separate fires involving e-bikes and e-scooters. In the UK, fires linked to lithium batteries increased by 46% in 2023. Research showed that of the 921 fires linked to lithium-ion batteries, nearly a third involved e-bikes, 125 were linked to electric scooters , and 118 related to electric cars. In 2024, the London Fire Brigade recorded 142 fires involving e-bikes and 29 involving e-scooters, averaging an e-bike or e-scooter fire once every other day.

With the numerous benefits that these types of batteries offer, it is therefore important to understand the health and safety risks associated with their manufacture, use, storage, disposal and recycling.

What are the Risks?

Thermal Runaway:

Thermal runaway is a key risk in lithium-ion batteries. This occurs when a battery’s internal temperature rises uncontrollably, which leads to a chain reaction of exothermic (heat-producing) reactions. The result can be the release of flammable gases, increased pressure, and potentially fires or explosions.

Several factors can trigger thermal runaway including short circuits, physical damage to the battery (e.g. dropping, crushing, puncturing the battery), high operating temperatures, manufacturing defects, improper charging (e.g. using non-approved chargers or over-charging).

Toxic Gases: 

During a fire, lithium-ion batteries can release toxic gases, including carbon monoxide and volatile organic compounds (VOCs).

Reignition:

Due to the self-sustaining process of thermal runaway, lithium-ion battery fires are also difficult to control. Larger batteries such as those used in electric vehicles may reignite hours or even days after the event, even after being cooled.

Safety measures for handling and storage

There are many guideline and recommendations for handling and storing lithium-ion batteries in the workplace.

Key considerations include:

• Choosing reputable manufacturers for supply when considering purchasing vehicles and equipment with lithium batteries.
• Frequently inspecting batteries for signs of damage or overheating.
• Never using damaged or defective batteries. Refer to the manufacturer’s instructions for dealing with damaged batteries. They often provide specific guidance for safe handling and disposal in these circumstances.
• Ensuring that battery handling and storage areas are dry, cool, well-ventilated, and free from high levels of humidity.
• Ensuring battery handling and storage areas are free from flammable or combustible materials and sharp objects, and that batteries are not left in contact with conductive materials.
• Ensuring battery charging is well managed and employees are suitably instructed and trained. Ensuring that batteries are removed from chargers after charging is complete and are not left on charge in unoccupied locations.
• Ensuring only approved chargers are used, and that all charging appliances meet suitable safety standards.
• Training employees in appropriate emergency procedures, providing specific instructions for dealing with damaged or faulty batteries. Employees should also be aware of their own safety in relation to dealing with fires involving lithium-ion batteries.
• Keeping batteries that are not in use in appropriate containers, such as a proprietary metal battery storage cabinet or fireproof safety bags.
• Limiting the size of storage areas, and ensuring they are dedicated to lithium-ion battery storage only where appropriate.
• Reducing the potential for thermal runaway by reducing the State of Charge (SOC) of Lithium-ion batteries and devices containing them. It is recommended not to let the battery be discharged completely. Keeping the SOC above 25% can help maintain general battery health.
• Keeping escape routes clear at all times, including storing lithium-ion batteries and lithium-ion battery powered devices away from escape routes.
• Never tampering or attempting to modify lithium-ion batteries.

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