Why Do Lithium-Ion Batteries Catch Fire?

By Owais AliReviewed by Lexie CornerOct 1 2024

This article overviews the causes of lithium-ion battery fires, examines the associated risks, and discusses preventive measures and industry contributions toward improving lithium battery safety.

Image Credit: JLStock/Shutterstock.com

Lithium-ion batteries (LIBs) are integral to modern technology, powering consumer electronics, electric vehicles (EVs), and renewable energy systems due to their high energy density, low self-discharge, rapid charging, and long lifespan. However, due to the volatility of their internal components, LIBs also present safety risks, notably the potential for fires and explosions.

Even though the reported incidents of LIB fires are low—ranging from one in one million to one in ten million units—understanding the causes of these incidents is crucial for improving battery safety in consumer and industrial applications.¹

Causes of Lithium-Ion Battery Fires

Thermal Runaway

Thermal runaway is a significant cause of LIB fires. It occurs when heat generated by the battery exceeds its cooling capacity, leading to a rapid temperature rise.

This happens when the battery's internal temperature exceeds 90-120 °C, triggering exothermic reactions in the electrolyte that decompose the solid electrolyte interface (SEI) and other components, releasing more heat.

As temperature escalates beyond 200 °C, the breakdown of the hydrocarbon electrolyte releases flammable gases, potentially leading to explosions.

Internal Short Circuits

Internal short circuits, caused by manufacturing defects, physical damage, or improper handling, can cause the separator to collapse and allow direct contact between the anode and cathode. This contact generates localized heating, triggering a thermal reaction and igniting the flammable electrolyte.

Overcharging and Overheating

Overcharging a LIB beyond its voltage limit causes excess lithium ions to accumulate on the anode, forming metallic lithium. This can lead to dendrites—needle-like structures that may pierce the separator and cause internal short circuits.

Additionally, prolonged exposure to high temperatures accelerates material degradation, increasing fire risk; even ambient temperatures above 40 °C can harm battery health, while extreme temperatures may lead to rapid failure and combustion.

External Damage

External physical damage, such as impact, puncture, or bending, can compromise battery safety by deforming the casing and exposing internal components. This can lead to electrolyte exposure to oxygen, resulting in increased fire risk.^2,3

Preventive Measures

Battery Design Improvements

Recent advancements in battery design have improved thermal management and safety features.

Modern LIBs have protective devices like safety vents, current interrupt devices (CID), and positive temperature coefficient (PTC) elements that help prevent thermal runaway by releasing pressure, interrupting current flow during overheating, and increasing resistance to limit heat generation.

Improved cooling systems and non-flammable electrolyte additives like phosphorus and fluoride further reduce the risk of thermal incidents.^2,4

Safety Standards and Regulations

Strict global safety standards ensure that LIBs meet essential safety criteria for operation.

The International Electrotechnical Commission (IEC) 62133 and UL 1642 are prominent standards that enforce testing protocols to prevent overcharging, short-circuiting, and overheating. They also mandate proper labeling and safety features for batteries used in consumer electronics and electric vehicles.

Additionally, countries and regions, such as the United States and the European Union, have established further testing and certification requirements, such as RoHS directives and UL certifications, for commercial use and transportation of LIBs.^5-7

Proper Usage and Handling

Adhering to manufacturer guidelines is essential for preventing LIB fires. Key practices include charging within the recommended voltage range, properly disposing of damaged batteries, and keeping charge levels below 50 % during moderate temperature storage to minimize fire risks.⁸

Industry Contributions

Several companies and organizations are actively working to enhance LIB safety by developing advanced fire prevention technologies.

PACT's Solutions for Thermal Runaway

Packaging and crating technologies (PACT®) has introduced innovative products, such as Thermo Shield™ and TR Sleeve™, to address thermal runaway in electric vehicles.

Thermo Shield™ is a lightweight fire-suppressant paper that cools package interiors and withstands temperatures over 1,500 degrees Fahrenheit, while the TR Sleeve™ prevents thermal runaway in battery cells. Both products have passed rigorous testing and comply with proposed safety standards for LIB transport.

PACT recently partnered with BS Technics to introduce these innovations in the Korean market, supporting major brands such as Samsung and Hyundai with a focus on sustainability and safety in the electric vehicle sector.⁹

Jensen Hughes' Customized Fire Protection Solutions

Jensen Hughes provides performance-based life safety consulting and risk assessment for LIB applications. The company specializes in custom fire protection systems tailored to address the unique threats posed by these batteries, including explosion control measures and gas detection systems. In addition, its control strategies, such as deflagration venting, are very effective in mitigating thermal runaway.¹⁰

Dafo Vehicle's Early Detection Systems

Dafo Vehicle Fire Protection AB collaborated with the Research Institutes of Sweden (RISE) on the EU-funded Li-IonFire project to create a fire protection system for LIBs in EVs.

The initiative focuses on early detection of battery failures and rapid intervention to prevent fires, demonstrating that timely activation can stabilize the battery before escalation. It has garnered significant interest from global manufacturers and end-users.¹¹

FirePro's Condensed Aerosol Fire Suppression

FirePro's condensed aerosol fire suppression technology is another effective solution for mitigating the fire risks of LIBs. This system works by interrupting the chemical reactions in flames, activating a rapidly expanding agent composed of potassium carbonate, which neutralizes harmful byproducts from battery fires, prevents the generation of flammable gases, and facilitates temperature reduction below critical levels for thermal runaway.

FirePro systems are deployed globally, including at the Princess Elisabeth Antarctica research project and Samsung SDI in Korea, providing effective fire suppression for large-scale LIB systems while adhering to operational and environmental requirements.¹²

Recent Research and Developments

Enhancing Lithium-Ion Battery Safety with Graphene

Ongoing research continues to address the safety challenges posed by LIBs. For instance, Swansea University researchers recently developed a method for producing large-scale, defect-free graphene current collectors that enhance lithium battery safety.

These foils have an exceptional thermal conductivity of up to 1,400.8 W m⁻¹ K⁻¹, nearly ten times higher than traditional materials like aluminum and copper. This addresses thermal runaway risks in LIBs, particularly for electric vehicles.

The scalable production allows for lengths up to kilometers, with durability maintained even after extensive bending, paving the way for safer and more efficient energy storage solutions.¹³

AI-Integrated Predictive Models for Overheating Prevention

In a recent study published in the Journal of Power Sources, University of Arizona researchers designed a machine-learning framework that predicts and prevents temperature spikes in LIBs. The system uses thermal sensors around battery cells to feed historical temperature data into an algorithm, enabling precise predictions of overheating.

This innovative approach significantly improves the battery management system's capacity to intervene before a fire can develop.¹⁴

Conclusion

The increasing reliance on LIBs in consumer electronics, electric vehicles, and renewable energy systems necessitates robust safety measures to prevent fires caused by thermal runaway, internal short circuits, and overcharging.

Ongoing advancements in safety technologies will be key to ensuring the reliable and sustainable use of these batteries.

More from AZoM: Unlocking Battery Potential: The Critical Role of Particle Size and Shape in Lithium-Ion Technology

References and Further Reading

1. Ghiji, M., Edmonds, S., Moinuddin, K. (2021). A review of experimental and numerical studies of lithium ion battery fires. Applied Sciences. https://doi.org/10.3390/app11031247
2. Ouyang, D., Chen, M., Huang, Q., Weng, J., Wang, Z., Wang, J. (2019). A review on the thermal hazards of the lithium-ion battery and the corresponding countermeasures. Applied Sciences. https://doi.org/10.3390/app9122483
3. Senyurek, U., Soyhan, HS., Celik, C. (2022). Battery Caused Fires in Electric Vehicles. https://doi.org/10.52702/fce.1054263
4. Lisbona, D., Snee, T. (2011). A review of hazards associated with primary lithium and lithium-ion batteries. Process safety and environmental protection. https://doi.org/10.1016/j.psep.2011.06.022
5. Chen, Y., et al. (2021). A review of lithium-ion battery safety concerns: The issues, strategies, and testing standards. Journal of Energy Chemistry. https://doi.org/10.1016/j.jechem.2020.10.017
6. IECEE. (2024). IEC 62133-2:2017. [Online] IECEE. Available from: https://www.iecee.org/certification/iec-standards/iec-62133-22017
7. Liu, J. (2023). Types of International Battery Safety Standards and Regulations You Need to Know. [Online] Mokoenergy. Available from: https://www.mokoenergy.com/battery-safety-standards/
8. HIS. (2024). Lithium Batteries: Safe Handling, Storage, and Disposal. [Online] HIS. Available from: https://hsi.com/blog/lithium-battery-safety
9. Olivero, T. (2024). Revolutionize EV Safety: PACT® & BS Technics Join Forces to Tackle Lithium-Ion Battery Fires. [Online] The OGM. Available from: https://theogm.com/2024/03/18/revolutionize-ev-safety-pact-bs-technics-join-forces-to-tackle-lithium-ion-battery-fires/
10. Jensen Hughes. (2024). Lithium-ion Battery Technology. [Online] Jensen Hughes. Available from: https://www.jensenhughes.com/services/lithium-ion-risk-consulting
11. Dafo Vehicle. (2024). Dafo Vehicle introducing Li-IonFire™ - increasing the safety of electric and hybrid electric vehicle operations. [Online] Dafo Vehicle. Available from: https://www.dafo-vehicle.com/news/dafo-vehicle-introducing-li-ionfire-increasing-the-safety-of-electric-and-hybrid-electric-vehicle-operations
12. FirePro. (2024). Fire Suppression Systems for ESS. [Online] FirePro. Available from: https://www.firepro.com/applications/energy-storage-systems/
13. Li, L., et al. (2024). Large-scale current collectors for regulating heat transfer and enhancing battery safety. Nat Chem Eng. https://doi.org/10.1038/s44286-024-00103-8
14. Goswami, BRD., Abdisobbouhi, Y., Du, H., Mashayek, F., Kingston, TA., Yurkiv, V. (2024). Advancing battery safety: Integrating multiphysics and machine learning for thermal runaway prediction in lithium-ion battery module. Journal of Power Sources. https://doi.org/10.1016/j.jpowsour.2024.235015

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