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 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 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) 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? Materials Power Difficulty of Manufacture Handling Considerations

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

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 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 Fire Smoke High Temperatures Explosion Initiate adjacent cells

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

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 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

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