Lithium Batteries
What are the Basics that I Should Know?
Flight Safety Foundation
Business Aviation Safety Seminar
Thomas Anthony
USC Aviation Safety and Security Program
Overview
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Types of Lithium Batteries
Uses
What makes Lithium Ion batteries different
How constructed
How they Fail
Hazards Associated with Failure
Main causes of failure
Overview (continued)
• Actions to take in case of failure
• Standards, regulations and lessons learned
• Statistics and cases
Two types of Lithium Batteries
• Lithium Metal Batteries
– Non-rechargable, one use
– Watches, flashlights , ELT’s, DFDR/CVR pingers
• Lithium Ion Batteries
– Rechargable
– Cell phones, cameras, laptop computers, power
tools, motorcycles
Lithium Metal Batteries
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Lithium primary
Can look similar to a non-lithium battery
Single unit (cells)
Generally smaller than lithium ion
Lithium metal – non-rechargable
Lithium Ion Batteries
• Not a simple cell
• Best called battery packs ( a battery is not a battery in
the common usage)
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Multi-component electrical device
Contains a micro-processor (onboard computer)
Numbers in existence
Start degrading immediately after
manufacture, 2-3 years useful life, exceptions
Lithium Ion
• Prefer partial discharge
• Complete discharge – ruined
• Sensitive to heat
Lithium Ion Battery Components
What makes Lithium Batteries
Different?
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Materials
Power
Difficulty of Manufacture
Handling Considerations
Materials
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Li-on pressurized, metal case
Vent for overpressure
Primary Lithium –lithium metal electrode
Lithium ion – Lithium Cobalt Oxide LiCoO2,
also Lithium Iron Phosphate, Lithium
Manganese Oxide
• Li-ion Anode – carbon, graphite
• Flammable electrolyte
Power
• Lithium ion stores 150 watt hours per 1 kg
• NiMH Nickle Metal Hydride -100 watt hours
per 1 kg
• Lead Acid – 25 watt hours per 1 kg
Difficulty of Manufacture
• First discovered in 1970’s
• 1979-1989 development around the world
• 1991 Sony & Asahi Kasei introduces first
commercial lithium ion
• 2002-2004 MIT substantial improvements
• 2011- li-ions were 66% of rechargeable market
in Japan
Handling Requirements
• Tesla recall adds aluminum shielding to deflect
road debris
• Careful handing to prevent dropping and
puncture especially as cargo
• Sensitive to heat and cold, no charging below
0 Celsius.
• Must ensure external electrodes do not
connect
How They Work
• BASF Video
How They Fail
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Thermal run-away
Excessive discharge
Short circuit, usually internal short
Short circuit uncontrolled flow of electrons
from one electrode to another
• High pressure buildup
How They Fail
• Separator sheet keeps positive and negative
electrodes apart -puncture
• High energy discharge not moderated by
internal regulator
• Temperatures initiate adjacent cells
• Venting
• Flammable electrolyte
• Fire, continued thermal run-away
• Puncture to vent-fire could take seconds to
hours
Hazards
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Fire
Smoke
High Temperatures
Explosion
Initiate adjacent cells
Main Causes of Failure
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Short circuits most common cause of fires
Puncture causing internal short circuit
Handling also common cause of failure
Incorrect charging
Substandard materials or substandard –
counterfeit manufacture
Actions to Take
• IATA Guidance on Handling Dangerous Goods
Incidents and Lithium Battery Fires in the Passenger
Cabin May, 2012
• Lithium Batteries are classified as Dangerous
Goods and regulated for transport by air.
• UN 3090 Lithium metal
• UN 3480 Lithium ion
IATA Guidance
• IATA’s DG regulation are IAW ICAO technical
instruction
• Crew members and pax are permitted to carry
lithium battery powered equipment in
checked and carryon baggage
• Crew members and pax are permitted to carry
spare batteries for those devices
IATA Guidance
• Spare batteries musts be carried in carry on
baggage
• To be permitted in crew and pax baggage:
• Lithium metal batteries must not have more
than 2 grams of lithium , not larger than AA
• Lithium ion must not have watt-hour rating of
more than 100 watt hours – typical laptop is 53
watt hours
– Airlines may grant exceptions for up to 160 watt hours
IATA Guidance
• Spare batteries must be in carryon baggage
and not more than 2 spares per person
• Airlines should have clear procedures
• A lithium battery fire should NOT be treated
as a Class D fire.
IATA Guidance – Fighting a Lithium
Battery Fire
• Remove external electrical power source
• Extinguish the fire
• Cool the remaining cells to prevent thermal
runaway
• Halon or Halon replacement and/or water
extinguishers can be used to control the fire
and prevent it spread to surrounding
flammable material
IATA Guidance- Fighting a Lithium
Battery Fire
• Follow extinguishment of the fire with
immediate dousing with water and/or other
non-flammable liquid from any available
source to douse the fire
• Monitor for re-occurrence and continue to
pour liquids until cells cool
– Examples: water, juice, coffee, tea, soft drinks
IATA Guidance- Fighting a Lithium
Battery Fire
• Do not pick up or attempt to move a burning
or smoking device
• Do not use ice, this insulates
• Notify the pilot in command
• Notify authorities upon landing
Video 2
• LAX Laptop Fire
Video 3
• Li-ion battery burnout (4:56)
Video 4
• Lithium Battery Fire by afisher 619
Lessons Learned
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Never disassemble a cell or battery pack
Avoid placing on hot surfaces
Use PPE when responding
Heat is the enemy, large amounts of water
Avoid batteries, flashlights, and other battery
powered devices from countries and sources
you are not 100% sure of
• None of the incidents involved consumer-type
batteries in their retail packaging
• Only use original equipment chargers
• DHL will not accept defective or damaged cells
(confirmed or suspected)
• A hot cell is a red flag
• Dropped cells or battery packs should be
treated as a hot cell.
• Smoke is a major hazard as well as fire and
high temperatures
Summary
• Reduce number and size of lithium batteries
on board
• Protect from mishandling and puncture
• Only charge with manufacturer equipment
• Lithium ion battery packs composed of
multiple cells
• Thermal runaway
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Thermal runaway, pressure buildup, smoking
Explosion, venting of flammable electrolyte
Extinguish flames – Halon or water
Continue to cool with water to prevent
thermal runaway to adjacent cells