Lithium Ion (Li-ion), including Lithium polymer (Li-Po)

• Generally rechargeable batteries
• Found in a wide range of electronic devices, such as laptops, tablets, cell-phones, e-Mobility Devices (Scooters, Bikes, etc), drones, etc

Lithium Metal (LiM)

• Generally non-rechargeable
• Have a longer life than standard alkaline batteries
• Commonly used in hearing aids, watches, smoke detectors, key fobs, etc

Lithium Batteries sold in the US are required to have passed the design tests found in the United Nations (UN) Manual of Tests and Criteria, Section 38.3. This testing assesses several attributes that can be significant for safe operation and transportation of the batteries:

• Altitude simulation
• Thermal test
• Vibration test
• Shock test
• External short circuit
• Impact/crush
• Overcharge
• Force discharge

Manufacturers are required to provide this information on a test summary. (See below for example test summary.) Do not purchase or use a battery if the manufacturer cannot provide this test summary!

Notable Differences to Conventional Batteries

Conventional Batteries

Two hazards are predominantly associated with conventional battery systems (such as lead-acid, alkaline, NiCd/NiMH, etc):

Toxicity: Many of the historical battery systems utilized the red/ox properties of heavy metals that present a health hazard during use as well as disposal. Some of the electrolytes could also lead to the release of toxic gas if heated or degraded.

Corrosivity: The electrolytic solutions used in many historical battery systems could be fairly destructive to tissues as well as metallic electrical components.

In the event of an electrical short, these conventional battery systems could present a fire hazard.

Lithium-Based Batteries

The replacement of the heavy metals of earlier battery systems with lithium compounds significantly reduced toxicity. Many of the electrolytic solutions may still be corrosive to tissues, but are often less so compared to other metals.

Many of the components associated with lithium-based batteries are either inherently flammable or capable of reacting with air or water to generate heat and/or evolve flammable gases, presenting a notably higher fire risk than historical battery systems.

Sealed battery cells - to protect the reactive components for air and water, lithium-based batteries typically need to be sealed. If cell is breached, it will often trigger a fire. Many common components will release gas as the battery fails which can lead to pressure building inside the sealed cell until bursting.

Thermal runaway - the exothermic (heat-generating) reaction of the chemical reaction can quickly push an overheated battery to an uncontrollable/self-accelerating failure of the battery resulting in a fire.

Common signs of lithium battery failure

• Cell/Battery Swelling: typically indicative that battery components have begun to degrade causing outgassing. For enclosed batteries, look for signs that the device may be separating.
• Unusual/excessive heating: Lithium batteries will typically generate some heat when charging/discharging, but elevated temperature when at rest or excessive temperature (>45◦C/113◦F) during use can be signs of battery failure.
• Discoloration on battery exterior, signs of casing damage (melting)
• Noise: hissing or cracking sounds
• Odor/Smoke: strong or unusual odor coming from the battery, emission of smoke likely indicate that fire may have already started

What to do if my Lithium Battery is Failing

1. Immediately turn off device/unplug from power source ie. if a laptop, disconnect adaptor
2. Move the device to a safe, isolated area away from flammable and combustible materials and surfaces
   • In a laboratory, move the battery device to a cleared fume hood
   • In non-laboratory setting, moving from flammable surfaces (like carpet) to a less-flammable surface (tile, stone, or metal surfaces) can minimize damage if fire occurs.
3. Monitor the device:
   • If conditions worsen or fire occurs, contact Public Safety (911).
   • If battery appears to be stable (no new signs of failure, no heating), contact EHS for additional guidance (8-5294)

What to do if my lithium battery catches fire?

1. Move yourself to a safe location and immediately call 911
2. Do not try to put the fire out yourself. 
   • Lithium battery fires can spread quickly and aggressively, and could become explosive.
   • Common fire extinguishants may not be sufficient to prevent a battery from burning and fires may suddenly re-ignite.
   • Addition of water can accelerate the reaction of some lithium battery components and can present a significant electrocution risk for larger, multi-cell batteries.
   • The safest decision you can make is to move yourself to a safe location and immediately call 911.

Prepare For Emergencies: Lithium Battery Crash-Bins

EHS has several configurations of Lithium Battery Crash Bins, which are designed to give laboratories who work with Li-based batteries an easy and effective containment option for damaged/defective batteries.

Kit contains:

• Non-combustible metallic container
• Container is lined with inert beads designed to trap leaked electrolyte, suppress flame, and dissipate heat
• Ziploc bag containing additional inert beads to cover the top of the battery

Using Li-Battery Crash Bin

1. Open lid to Crash Bin
2. Remove Ziploc bag with additional inert beads
3. Place damaged/failed battery in Crash Bin
4. If battery excessively hot or other signs of imminent failure, empty contents of Ziploc to cover top of battery.
5. Carefully place metal lid over the top of the Bin.
   • Do not re-attach latching ring (2.5/5gal) or press on lids for smaller bins (1qt/1gal) so that pressure can be safely released!
6. If safe to do so, move Crash Bin to a safe location within the lab.
   • Free of flammable/combustible materials
   • Well-ventilated (ideally a fume hood)
7. If signs of fire, contact Public Safety (911). Otherwise contact EHS (8-5294) for additional guidance.

Transport by Passenger Plane

The Federal Aviation Administration (FAA) restricts the carriage of lithium-based batteries for carriage on passenger planes as do many other airlines and airline regulatory agencies.

Lithium based batteries are often restricted to carry-on only and may not be present in checked luggage. 

Most consumer electronics use batteries intentionally sized so that they are not restricted when carried by the passenger (lithium metal 2g or less lithium per battery, lithium ion 100 Wh or less).
 
Higher capacity lithium batteries (Lithium metal 2-8g lithium per battery, lithium ion 101-160Wh) may be limited (typically to two per passenger) or restricted. These batteries can often be found in larger charge/power banks, aftermarket extended-life laptop batteries, and professional grade A/V equipment. If traveling with these higher capacity batteries, travelers should contact their airline for additional guidance.

Batteries exceeding 8g lithium metal per battery or 160Wh will typically be prohibited from passenger planes. Passengers with these devices should contact their airline for additional guidance.

Use the FAA PackSafe resource for more information.

Shipping by Commerical Carrier

Lithium batteries including batteries contained in equipment are regulated for shipment as a hazardous material, including common consumer electronics, including:

• Laptops
• Tablets
• Mobile Phones
• Drones

Hazardous material shipments must be prepared by trained HazMat Shippers and adhere to specific packaging, documentation, and record-keeping requirements.

To ship lithium batteries or devices containing lithium batteries, submit a Hazardous/Regulated Material Shipping Request to EHS. An EHS HazMat Shipper will contact you to arrange for shipment.

To faciliate processing your shipping request:

1. Provide battery specifications if known (Wh- watt-hour rating) If not known, provide:
   • Output voltage and Current (Amp-hour) rating; or 
   • Manufacturer/model info.
2. Retain original manufacturer’s packaging (as this will often meet packaging requirements). Substitute packaging can be obtained from FedEx, Uline, WB Mason, etc.
3. Prepare your battery device.
   • Cover exposed leads/terminals to prevent shorting
   • Discharge battery to 30% or less maximum charge

Lithum-based batteries must be processed as hazardous waste and cannot be disposed in regular trash or placed in one of the conventional (Lead-Acid/NiCd/NiMH) Battery Collection Pails.

Preparing a non-damaged cell/battery for disposal:

1. Discharge the cell/battery.
2. Use a non-conductive tape to cover leads/terminals to protect against accidental shorting.
3. Place cells/batteries in a ziploc bag with a completed Hazardous Waste Label in a safe location (away from flammable/combustible materials)
4. Submit a Hazardous Waste Pickup Request.

If cell/battery is damaged or showing signs of failure, contact EHS for additional guidance prior to submitting a Waste Pickup Request.

When to notify EHS about your Lithium Battery Usage

• High Capacity Cells/Batteries:
  • Cells: Lithium-ion > 60Wh Lithium-metal > 5g Li/cell
  • Batteries: Lithium-ion > 300Wh Lithium-metal > 25g Li/battery
  • Cell/Battery Arrays: Lithium-ion > 300Wh Lithium-metal > 25g Li/battery
• Large collections of smaller Lithium-based batteries not typically located within equipment (spares):
  • Sum of Cells/Bats: Lithium-ion > 500Wh Lithium-metal > 50g Li
• Operation of Lithium-based batteries outside normal operating temperature range
• Operation of Lithium-based batteries where there is a reasonable risk of battery damage
• Modification/Alteration of commercially available lithium based batteries
• Synthesis/Fabrication of Novel Lithium-based Cells/Batteries/Energy Storage Devices

PPE when handling novel or potentially damaged/ malfunctioning lithium-based cells and batteries

1. Eye protection
2. Body Protection - Fire Resistant Lab Coat (such as NomexIIIA, FR-Cotton, FR/CP)
3. Hand Protection - Providing chemical resistance and protection from fire (Recommended: FR glove line with chemical resistant outer glove)

When Buying

• Purchase products from reputable manufacturers and vendors. Well-engineered and well-tested products are consistently the safer products.
• Look for products that have been reviewed by a Nationally Recognized Testing Laboratory (NRTL). Certifications from a NRTL, such as Underwriters Laboratory (UL), indicate that a product has been tested and shown to meet safety, quality, or security standards. Items that have been certified will often have a safety mark on the object, the product packaging, or product manuals.  
• Check for product recalls before buying. The US Consumer Product Safety Commission regularly reports when a lithium battery product has been identified as a fire safety hazard. Before buying, check to see if a product has been recalled by reviewing the CPSC database at https://www.cpsc.gov/recall.  After purchase, follow manufacturer’s guidance on registering your device in order to make sure you are notified if a product is recalled.

When Using

• Follow the manufacturer’s instructions on how to charge, store, and use a lithium battery powered device. Do not disassemble or modify the device’s battery, battery compartment, or electrical system as this may increase risk of a battery failure.
• Inspect battery regularly for signs of damage or indications of lithium battery failure.

When Charging

• Only use the charger that was provided with the device. If you need to buy a replacement charge, make sure the charger is approved by the device manufacturer. Just because a charger fits doesn’t mean it is safe to use!
• Do not leave lithium powered devices unattended while charging.
• Plug charger directly into a wall electrical outlet rather than connecting through an extension cord or power strip.
• Pick a safe place to charge your device. Charge on a flat, dry area away from direct sunlight, liquids, or combustible/flammable materials
• Charge (and store) batteries at room temperature when possible. Do not charge at temperatures below 32◦F (0◦C) or above 105◦F unless approved by the manufacturer.