Understanding lithium-ion battery hazards and emergency management solutions

Unlike traditional lead-acid batteries, when damaged lithium-ion batteries can enter a state known as thermal runaway. This is a chain reaction where one damaged cell can quickly ignite adjacent cells, producing intense heat and toxic gases such as hydrogen fluoride. These fires are notoriously difficult to extinguish and often require submersion in water or sand to control, or simply patience while the fuel is consumed. Battery Energy Storage Systems (BESS) units, like those being built across the country to augment the national power grid are particularly vulnerable due to their scale and energy density, meaning a single cell failure can cascade across an entire system resulting in the loss of the BESS and associated infrastructure. The self-sustaining nature of lithium-ion batteries in a thermal runaway also means that when mixed with other combustible commodities, as is often the case in a train derailment, fires can be prolonged, and of greater intensity.

Responding to lithium-ion battery incidents requires specialized strategies to protect people and minimize damage. These can include:

• Updating response plans to include lithium-ion battery fires to address the specific risks of lithium-ion battery fires and ensure stakeholders understand their roles.

• Staying upwind of smoke plumes to avoid exposure to hazardous gases. As there is an abundance of noxious gases from lithium-ion battery fires, this is key to first evaluating an incident, as well as maintaining health and safety of those responding to the incident.

• Using real-time air monitoring, detecting hydrogen fluoride, hydrochloric acid, and many of the other toxic gases produced during an incident remains technically challenging and costly. Colorimetric tubes offer a more readily deployable and affordable alternative for initial detection. 

• Conducting constant temperature monitoring using thermal imaging or infrared tools to detect signs of thermal runaway.

• Recognizing delayed ignition risks. Damaged batteries may appear stable but can ignite hours or even days later. Specialized disposal methods like the “Maui method”, pioneered by the United States Environmental Protection Agency involve physically dismantling and neutralizing the battery. The potential for thermal runaway is always there until you separate the battery component and destroy it.

• Stockpiling response supplies like fire blankets and sand for containment may be prudent in preparing to respond to a fire. Fighting lithium-ion battery fires requires exponentially more water than traditional fires so securing a steady, replenishable source is critical. 

• Introducing BESS-specific risk management strategies, such as:

• Complex enclosure designs: Containers can trap heat and gases, making proper venting critical.

• Access challenges: Responders may not be able to easily reach burning cells inside steel housings.

• Electrical hazards: Residual charge may remain in high-voltage systems even after shutdown.

• Anticipating and containing potential firefighting water runoff is essential to limiting environmental damage. As lithium-ion battery fires require large amounts of water to extinguish, responders should plan to manage this accordingly.

Our emergency response teams have responded to incidents involving large-scale battery systems, shipboard fires, and many other incidents large and small involving lithium-ion batteries. In one Canadian case, a container-sized battery fire led to months of temperature monitoring while stakeholders including manufacturers and responders determined next steps. In another case in Alaska, responders sealed a ship’s cargo hold and waited weeks before cautiously opening it. In several BESS unit incidents, responders faced prolonged off-gassing and re-ignition risks, requiring days of cooling and continuous air and thermal monitoring before safe entry could be made.

We offer a full suite of services to support clients in managing lithium-ion battery risks, including: 

• Emergency action plan revision tailored to battery-specific hazards 

• On-site response including real-time air monitoring, incident command support, environmental support, remediation and oversight during incident

The consequences of lithium-ion battery incidents can be severe. Fires have occurred on car carriers that initially appeared manageable before quickly leading to the loss of entire ship’s cargo and even sinking. The industry continues to develop innovative packaging and response techniques to reduce these risks. As global energy storage capacity is expected to grow tenfold by 2030, proactive planning for lithium-ion battery emergencies will become a critical part of resilience strategies. With sound risk management and response strategies, organizations can minimize hazards and protect their people and assets.

As the industry continues to adapt, we remain committed to sharing insights and lessons learned. Our team will present further findings on this topic at the Clean Gulf Conference on November 20. Join us there or reach out to learn how we can help strengthen your emergency response strategies.