1. 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

3. Overview Types of Lithium Batteries Uses
What makes Lithium Ion batteries different
How constructed
How they Fail
Hazards Associated with Failure
Main causes of failure

4. Overview (continued) Actions to take in case of failure
Standards, regulations and lessons learned
Statistics and cases

5. 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

6. Lithium Metal Batteries
Lithium primary
Can look similar to a non-lithium battery
Single unit (cells)
Generally smaller than lithium ion

9. Lithium metal – non-rechargable

11. Lithium Ion Batteries Not a simple cell
Best called battery packs ( a battery is not a battery in the common usage)
Multi-component electrical device
Contains a micro-processor (onboard computer)
Numbers in existence
Start degrading immediately after manufacture, 2-3 years useful life, exceptions

12. Lithium Ion Prefer partial discharge Complete discharge – ruined
Sensitive to heat

13. Lithium Ion Battery Components

16. What makes Lithium Batteries Different?
Materials
Power
Difficulty of Manufacture
Handling Considerations

17. Materials 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

18. 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

19. Difficulty of Manufacture
First discovered in 1970’s
development around the world
1991 Sony & Asahi Kasei introduces first commercial lithium ion
MIT substantial improvements
2011- li-ions were 66% of rechargeable market in Japan

20. 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

21. How They Work
BASF Video

22. How They Fail Thermal run-away Excessive discharge
Short circuit, usually internal short
Short circuit uncontrolled flow of electrons from one electrode to another
High pressure buildup

23. 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

24. Hazards
Fire
Smoke
High Temperatures
Explosion
Initiate adjacent cells

25. Main Causes of Failure 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

26. 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

27. 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

28. 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

29. 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.

30. 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

31. 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

32. 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

33. Video 2
LAX Laptop Fire

34. Video 3
Li-ion battery burnout (4:56)

35. Video 4
Lithium Battery Fire by afisher 619

36. Lessons Learned 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

37. 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

38. 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

39. 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