More and more of our clients have a new hazard to address, the safe storage of lithium-ion batteries. Indeed the total amount of batteries stored is expected to increase 7X over the next 7 years. We have all heard the annoucements on aircraft about overheating batteries in consumer devices and the batteries which we use in our businesses can be several times larger with consequently higher risks.
Good practice dictates that a dedicated area is used and signed appropriately, that batteries are disconnected from the tools they power when stored and that their charge state is kept at around 60-70%. Once disconnected you can then apply simple good practices, not dissimilar to the storage of chemicals which you already have in your workplace. Consider the following, storage at normal room temperature (avoid temperature extremes), good ventilation, adequate space and segregation and finally fire detection and suppression. Naturally, all of these points of good practice will vary dependent on the type, size and quantity of lithium-ion batteries which you store.
Finally, don’t forget your planning should the worst occur. Specialist lith-ex extinguishers are available and typically use AVD (Aqueous Vermiculite Dispersion) to tackle fires. If you are storing higher quantities then a specialist fire risk assessment is required and this might also mean contacting your local fire authority to register the presence of these items. If you need this kind of Fire Risk Assessment please do get in touch or request a call back.
Find out more about the safe storage of lithium-ion batteries below.
Introduction
Lithium-ion batteries play a crucial role in various industrial applications, including energy storage, manufacturing, and logistics. However, their high energy density presents significant fire and safety risks if not stored correctly. Industrial facilities must implement robust safety measures in line with UK Health and Safety Executive (HSE) guidelines to prevent potential hazards.
Understanding the Risks
Improper storage of lithium-ion batteries in industrial settings can lead to:
- Thermal runaway, resulting in overheating, fire, or explosion.
- Chemical leaks, which pose risks of toxic gas release.
- Electrical short circuits, due to improper handling or accidental damage.
- Mechanical damage, leading to punctures that can cause internal short circuits.
Adhering to industry best practices and regulatory guidelines can significantly reduce these risks.
Best Practices for Industrial Storage
1. Storage Facility Requirements
- Store lithium-ion batteries in designated, well-ventilated areas away from combustible materials.
- Maintain temperature-controlled storage between 15°C and 25°C to reduce the risk of overheating.
- Ensure storage areas are equipped with fire-resistant barriers and non-conductive shelving.
- Use explosion-proof ventilation systems where large battery volumes are stored.
2. Segregation and Classification
- Separate batteries by charge level, size, and chemistry to prevent thermal propagation.
- Store defective or damaged batteries in clearly marked, fireproof containers.
- Maintain a safe distance between storage racks to allow for adequate air circulation and fire containment.
3. Fire Prevention and Suppression Systems
- Install automatic fire detection and suppression systems, such as water mist or gas-based extinguishers suitable for lithium-ion battery fires.
- Provide Class D and lithium-specific fire extinguishers within reach of storage areas.
- Implement early detection systems, including temperature and gas sensors, to identify potential failures before they escalate.
4. Safe Handling Procedures
- Train employees on proper battery handling to prevent mechanical damage or accidental short circuits.
- Use insulated tools and personal protective equipment (PPE) when handling large battery packs.
- Regularly inspect batteries for physical damage, leakage, or swelling, and remove compromised units immediately.
5. Emergency Response Planning
- Develop a comprehensive fire and hazard response plan that includes evacuation procedures.
- Conduct regular fire drills and employee training on emergency handling of battery-related incidents.
- Establish partnerships with local fire services to ensure they are familiar with site-specific hazards and response requirements.
6. Regulatory Compliance and Documentation
- Follow HSE guidance on hazardous material storage (HSG71) and Dangerous Substances and Explosive Atmospheres Regulations (DSEAR).
- Maintain records of battery inventory, inspections, and incident reports for audit purposes.
- Comply with the ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road) if batteries are transported offsite.
Conclusion
Industrial lithium-ion battery storage requires rigorous health, safety, and fire risk management protocols. By implementing HSE-compliant practices and proactive safety measures, businesses can mitigate risks, protect personnel, and ensure operational continuity. Regular staff training, emergency preparedness, and adherence to regulatory guidelines are key to safe and efficient battery storage in industrial environments.
HSE guidance link: https://www.hse.gov.uk/pubns/indg139.pdf
