Lithium-ion Battery Safety: Ensuring Safe Handling and Storage

by Fiona Nelmes

Understanding Lithium-ion Battery Risks

Lithium-ion (Li-ion) batteries, or LIBs, are well-known for their high efficiency and compact design. They have transformed energy storage and are now prevalent in various industries, particularly in the automotive sector. However, with this great power comes great responsibility. The thermal instability of lithium-ion batteries can lead to significant hazards if they are not stored or handled properly. Issues such as leaks, overheating, and thermal runaway can occur. Thermal runaway is a chain reaction caused by overheating, overcharging, or mechanical damage. It can generate excessive heat and flammable gases, which can ultimately lead to fires or explosions. These incidents can leave behind toxic materials.

Due to the rising number of such incidents, insurers like Allianz stress the need for careful review of how we store, handle, and transport LIBs. These batteries are not only found in electric vehicles but are also commonly used in portable tools within workshops. Given the unique challenges these batteries present, ensuring their safe processing is crucial for the safety of personnel, the environment, and businesses.

Current Regulations and Future Developments

While the UK currently lacks specific regulations covering the safe storage of lithium-ion batteries, we are moving toward stricter safety oversight. The proposed Lithium-ion Battery Safety Bill outlines provisions that emphasize safety:

• Planning authorities must consult safety agencies before approving battery energy storage systems.

• Devices powered by lithium-ion batteries will be required to meet stricter safety standards.

• Guidelines for the safe disposal of lithium-ion batteries will be implemented.

  
  

Even without these formal regulations, the Health and Safety Executive (HSE) has provided guidance on best practices for handling and storing batteries. Storing lithium-ion batteries should be approached similarly to the proper storage of chemicals. The HSE suggests several best practices for employers:

• Store batteries in cool, dry, and well-ventilated areas, ideally between 5°C and 20°C.

• Ensure proper disposal of batteries in authorized recycling facilities.

• Provide appropriate personal protective equipment (PPE) for employees working with batteries.

• Train employees on safe battery handling, storage, and usage.

  
  

Best Practices for Battery Storage and Management

In addition to the above recommendations, proactive management measures can significantly enhance battery safety. Consider implementing these practices:

• Maintain a charge level of 40-60% for batteries in long-term storage. Regularly check their status and recharge them if the level falls below 20%. Storing batteries that are fully charged or completely drained can strain cells and increase the risk of degradation or failure.

• Use non-conductive, fireproof storage containers for lithium-ion batteries, keeping them away from metal tools. This helps minimize the risk of short circuits and fires.

• Keep battery terminals clean and free from dust or debris to ensure optimal performance and safety.

• Avoid placing batteries in areas prone to temperature fluctuations, such as near radiators, in direct sunlight, or in cold garages during winter.

• Store batteries away from flammable or combustible materials to mitigate the risk of fire spreading in case of an incident.

• Avoid storing loose batteries together since their terminals may come into contact, leading to a short circuit.

• Regularly inspect batteries for signs of damage, swelling, or corrosion. If any issues are found, isolate the affected batteries per the manufacturer's instructions. Ensure you arrange for the safe disposal of damaged batteries as soon as possible.

  
  

We anticipate that regulations requiring all batteries to be individually stored in specialist cases will become mandatory. For now, we recommend these cases primarily for damaged or end-of-life batteries.

Damaged and End-of-Life Batteries

In addition to visual signs such as dents, scratches, or expansion, a battery is considered damaged if:

• Dropped from a height of 30 cm or higher.

• Involved in a crash at 20 mph or higher.

• Punctured by a sharp object.

  
  

Treating battery damage as an emergency is crucial for fire prevention. Workers should notify their designated Health and Safety Officer immediately if they have concerns about a battery. If necessary, they should contact emergency services.

Batteries requiring disposal are classified as dangerous waste. They should be assessed for suitability for transport by a qualified battery expert as soon as possible:

• A green battery is a high-voltage battery (HVB) deemed "safe for transport" by a qualified person. This assessment is based on the manufacturer's protocols.

• A red battery is classified as "not safe for transport" and has different requirements to minimize the risk of incidents during transit.

  
  

If a battery is categorized as unsafe, a quarantine zone should be established. Only personnel trained in the safe handling of lithium-ion batteries should manage them until they are transferred to an approved disposal contractor.

To facilitate safe transportation, BAM-certified safety battery boxes for unsafe batteries will be required. These boxes are large and heavy, necessitating careful planning regarding space and the possible need for lifting aids. They should be stored at least 10 meters away from buildings and bystanders. Ideally, they should be enclosed in non-conductive, fireproof containers or kept in isolated areas surrounded by a concrete wall.

Because unsafe and end-of-life batteries require specialist transport, disposal contractors must meet the requirements of the UN38.3 standard. This standard outlines tests and criteria for the safe transport of lithium batteries, whether stand-alone or installed in devices.

Documentation must be provided to the disposal contractor, including Dangerous Goods-related records: Material Safety Data Sheets, COSHH Assessments, and Manufacturer Protocols. The disposal contractor should give certificates detailing information that uniquely identifies each battery being transferred, including Battery Identification, Part Number, Vehicle Identification Number (FIN/VIN), Dealer Name and Address, Dealer Number, Time, and Date.

The ADR Agreement outlines international regulations for the transport of dangerous goods by road. This includes packaging, load securing, classification, and labeling of such goods. Adhering to these protocols ensures the correct information is conveyed to emergency services, transport personnel, and others who may come into contact with the goods. Verify that your disposal contractor meets these obligations.

Emergency Preparedness

For businesses that handle lithium-ion batteries, having documented procedures and well-trained staff is essential. They must know what to do in the event of a battery malfunction, damage, or fire. Regularly reviewing policies, offering manufacturer training, and conducting Toolbox Talks or refresher training will keep staff informed and prepared.

For further insight into lithium-ion battery safety, this topic was recently discussed at an online event hosted by the Institute of Occupational Safety & Health (IOSH). Gillies Crichton, Managing Director of Resilire Assure Ltd, presented valuable information that can be accessed in a YouTube recording here.

Stay tuned for our regular blogs, and if you have any specific topics you would like us to cover, please reach out to us at info@kvf-consultants.co.uk.