Lithium-Ion Battery Safety: Expert Insights & Guidelines

Lithium-ion batteries have grown in popularity since their creation in the s. With several important advantages, such as being lightweight and able to hold a charge during long storage periods, lithium-based batteries are some of the most popular on the market. 

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Lithium batteries, lithium-polymer batteries, and lithium-ion batteries have emerged as popular energy sources in recent times. A regular lithium-ion battery can hold 150 watt-hours of electricity in a 1 kg battery, which is much higher compared to a lead acid battery with a storage capacity of 25 watt-hours per kg and NiMH battery with a storage capacity of 100 watt-hours/kg. With their many advantages, these batteries are now widely used in consumer electronics and battery-operated vehicles.

Despite its popularity, lithium safety has been one of the concerns for users and manufacturers across the world. These safety issues are largely due to instability and extreme sensitivity at high temperatures. Inadequate quality, flawed battery design, physical abuse, and improper discharging and charging are some leading causes of rapid explosion and fire in these batteries. Nowadays, lithium batteries and lithium-ion batteries are designed with some safety measures such as pressure-relief devices and positive temperature coefficient (PTC) resistors, which act as a fuse. Although these features help reduce risks to a large extent, it is still recommended to store damaged or end-of-life lithium batteries safely before sending them to the nearest recycling center.

From tiny nickel cadmium button batteries to rechargeable power packs for tools and electronics, you probably use and store plenty of batteries to power everyday operations at your facility. But, as new types of batteries enter the market and are used throughout industry, practices for safe storage, shipping and response may need to be developed and reviewed.

Lithium-ion (Li-ion) batteries are one example of these new battery technologies. They are lightweight, have a high energy density and can be recharged many times. In addition to laptops, tablets, and phones, Li-ion batteries are used in portable tools and even to power vehicles and heavy equipment.

Li-ion batteries contain an anode, cathode and electrolyte. These components are arranged within a casing that allows the battery to function normally. But, if the battery is stored incorrectly or handled improperly, it can become hazardous.

This article will teach you how to handle, store, ship and dispose of damaged lithium-ion batteries. It will also provide background information on the dangers associated with Li-ion batteries and some tips on how you can prevent battery damage.

Caring for Damaged, Defective, or Recalled Li-ion Batteries

How to Store Damaged Lithium-ion Batteries

Damaged Li-ion batteries have the potential to leak electrolyte or worse, enter thermal runaway, so it&#;s important to wear proper PPE (goggles, face shield, gloves, apron, etc.) during handling. For safe storage while awaiting proper disposal, place the battery in a container of cushioning material that is non-combustible, electrically non-conductive, and absorbent. Do not place damaged batteries in the regular trash or recycling containers. If further measures are needed, the damaged battery may be placed in a specially designed storage case.

Are Lithium-ion Batteries Hazardous Waste?

When lithium-ion batteries are at your facility, the EPA classifies them as universal waste (you can also choose to manage them as RCRA-regulated hazardous waste). When they are managed as universal waste, they need to be sent to a recycler, not a landfill.

The DOT also has a say in how you manage your lithium-ion batteries. Once your Li-ion batteries are on the dock and you&#;ve made shipping arrangements, you need to abide by DOT Hazardous Materials Regulations.

Shipping Damaged Lithium-ion Batteries

A question we frequently get from customers is, &#;How do you dispose of a damaged lithium-ion battery?&#; Damaged, defective, and recalled Li-ion batteries must be properly packaged and shipped so that they will not create safety problems during transportation. Facilities that offer these batteries for transport must follow the provisions in 49 CFR 173.185 when preparing these items for shipment.

These provisions can be met by taking steps such as using a UN Rated container with lid, affixing a Class 9 hazard label and surrounding the bagged battery in compliant shipping material. The shipment must be marked with an appropriate UN shipping label and other required markings.

Lithium-ion Battery Hazards

Two questions we hear often are: &#;What happens if you break a lithium-ion battery?&#; and &#;What are the dangers of lithium-ion batteries?&#;

Broken or cracked cases can allow moisture and oxygen to enter the battery and oxidize the lithium components, causing a heat reaction also known as thermal runaway. This can lead to fires or explosions. Overheating, overcharging and shock from dropping or crushing can also cause heat reactions to occur.

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Signs of a Li-ion battery entering thermal runaway are discoloration, deformation, bulging or swelling. If possible, batteries showing these signs should be isolated to prevent further propagation to other combustible materials.

Li-ion Battery Fires

Overcharged, overheated and damaged Li-ion batteries have the potential to catch fire because the lithium components of the battery are susceptible to oxidation. The electrolyte in the battery, which is usually composed of lithium salts and organic solvents, is also flammable. Lithium-ion battery fires can be hard to extinguish and can release irritating vapors and toxic fumes.

Areas where Li-ion batteries are stored and used should be equipped with fire blankets or containment bags. As with any fire, if it has progressed beyond the incipient stage, it should be fought by a trained fire brigade or fire response team.

FAQ on Handling and Storing Lithium-Ion Batteries

What Are Some Tips for Safely Handling Li-ion Batteries?

Improper handling can cause damage to batteries, which may lead to overheating, fires or explosions. Here are our tips for proper Li-ion handling:

Do:

• Remove batteries from devices that will not be used for an extended period
• Keep batteries away from electromagnetic sources
• Keep batteries intact
• Isolate batteries that show any signs of damage

Don&#;t:

• Drop or crush the battery pack
• Use batteries that are bulging, dented, swollen, leaking or damaged in any way
• Puncture battery cases
• Modify the battery in any way
• Leave batteries on the charger overnight or for extended periods of time

How Should Lithium-ion Batteries be Stored?

Proper storage prevents damage to batteries and prolongs their life expectancy (typically 1-3 years). Follow these battery storage dos and don&#;ts:

Do:

• Store in well-ventilated areas
• Store in temperatures between 40ºF and 80ºF
• Store away from direct sunlight and heat sources
• Avoid freezing
• Keep terminals covered when battery is not in use
• Prevent terminals from touching each other
• Keep away from high temperatures
• Store in a container designed to protect the surrounding area in the event a battery enters thermal runaway

Don&#;t:

• Mix with other types of batteries
• Store loosely
• Allow batteries to get wet
• Store in vehicles
• Store in areas with wide temperature fluctuation
• Store in hot areas

How Do I Clean Up a Lithium-ion Battery Spill?

Although infrequent, if the electrolyte from a damaged Li-ion battery spills out of a battery pack, it can present hazards to anyone in the area and those responding to the spill. Use the following precautions and procedures to clean up a lithium-ion spill:

• Isolate and ventilate the area
• Wear proper PPE (goggles, gloves, apron, etc.)
• Keep an appropriate firefighting measure within reach
• Place the battery in a container of chemically inert cushioning material like PIG Obsidian Loose Shipping Material
• Use inert, non-cellulose absorbents to clean up any spilled electrolyte material
• Place used absorbents and PPE in a sealed bag and contact your environmental or shipping officer for proper disposal of the battery and absorbents
• Do not place batteries or spent absorbents in the regular trash or recycling containers

Lithium-ion batteries have many advantages over traditional alkaline and other types of batteries. When stored, handled and used properly, they also have a longer service life and pack more power than other batteries. Establishing and following safe procedures for storage, shipping and spill response will help prevent fires and explosions.

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