Lithium Batteries - Run Away!
Air Busan 28 January 2025
The Hidden Dangers of Lithium Batteries on Planes: A Growing Concern for Aviation Safety
An Airbus aircraft owned by the South Korean airline Air Busan caught fire on Tuesday, January 28th, 2025, at Gimhae International Airport as it was preparing to depart for Hong Kong.
Fire authorities in Busan stated that all 169 passengers and seven crew members had been evacuated, with three sustaining minor injuries. Reports suggest that a lithium battery in an overheated bin ignited.
If true, this is deeply concerning. There have been several such incidents, and had the fire occurred in flight, the outcome would have been awful. Once again, the risks of lithium barriers and how to manage those risks are open to debate.
Lithium batteries have become an integral part of our daily lives in recent years. These compact power sources have revolutionised our lives and work, from smartphones to laptops to electric vehicles and medical devices. However, their widespread use has also introduced significant risks, particularly when it comes to air travel.
The dangers of lithium batteries on planes have become a growing concern for aviation safety. Incidents of fires, explosions, and near-misses have raised alarms among regulators, airlines, and passengers alike. This blog explores the risks associated with lithium batteries on aircraft, their challenges, and what can be done to mitigate these dangers.
The Science Behind Lithium Battery Risks
Lithium batteries, especially lithium-ion (Li-ion) and lithium-polymer (LiPo) are preferred for their high energy density, lightweight design, and capacity to retain a charge for prolonged periods. However, these traits also make them susceptible to a phenomenon known as “thermal runaway,” which is the leading cause of lithium battery fires.
Thermal runaway occurs when a battery cell overheats, leading to a self-sustaining chemical reaction that generates even more heat. Physical damage, manufacturing defects, overcharging, short-circuiting, or exposure to high temperatures can trigger this. Once thermal runaway begins, it can cause the battery to vent toxic gases, catch fire, or even explode. Such an event can have catastrophic consequences on an aeroplane, where space is confined and the environment is pressurised.
The Risks of Lithium Batteries on Planes
The dangers of lithium batteries on aircraft are multifaceted, affecting both passenger safety and the integrity of the aircraft itself. Below are some of the key risks:
In-Flight Fires
One of the most immediate and severe risks is the potential for in-flight fires. Unlike traditional fires, lithium battery fires are exceptionally challenging to extinguish. They can burn at extremely high temperatures and can reignite even after appearing to be extinguished. Standard fire suppression systems on aircraft, which are designed to handle conventional fires, may prove ineffective against lithium battery fires.
In 2010, a UPS cargo plane crashed in Dubai after a fire broke out in the cargo hold fueled by lithium batteries. Both pilots lost their lives, and the incident highlighted the unique challenges of dealing with lithium battery fires in the air.
Toxic Fumes
When lithium batteries catch fire, they emit toxic gases including hydrogen fluoride, carbon monoxide, and various other harmful chemicals. In the confined space of an aeroplane cabin, these fumes can rapidly turn lethal, presenting a significant threat to passengers and crew.
Explosion Hazards
In extreme cases, lithium batteries may explode, resulting in physical damage to the aircraft and potentially compromising the fuselage. This could lead to rapid decompression, putting everyone on board at risk.
Cargo Hold Risks
While most passengers know the risks associated with carrying lithium batteries in their carry-on luggage, the dangers are even more significant in the cargo hold. Bulk shipments of lithium batteries, often transported as cargo, can create a "domino effect" if one battery catches fire, potentially igniting others nearby. Crew members do not have immediate access to the cargo hold, making it difficult to respond to such incidents.
Counterfeit and Poor-Quality Batteries
The rise of counterfeit and low-quality lithium batteries has heightened the associated risks. These batteries frequently lack the safety features found in reputable brands, rendering them more prone to overheating and thermal runaway.
Regulatory Challenges and Industry Response
The aviation industry and regulatory bodies have been grappling with how to tackle the risks posed by lithium batteries. The International Civil Aviation Organization (ICAO), the Federal Aviation Administration (FAA), and other agencies have implemented guidelines and restrictions, yet challenges persist.
Restrictions on Battery Shipments
In response to the growing risks, ICAO and the FAA have imposed restrictions on transporting lithium batteries as cargo on passenger planes. For example, bulk shipments of lithium-ion batteries are now prohibited on passenger aircraft, and stricter packaging requirements have been introduced for cargo shipments.
Passenger Guidelines
Airlines have also issued guidelines for passengers travelling with lithium batteries. These include limits on the size and quantity of spare batteries, requirements to carry them in carry-on luggage (where they can be more easily monitored), and instructions to protect battery terminals from short-circuiting.
Fire Suppression Systems
Efforts are being made to develop more effective fire suppression systems for aircraft. Some airlines are experimenting with containment bags designed to isolate and suppress lithium battery fires. These bags can endure extreme temperatures and prevent the spread of toxic fumes.
YouTube has many clips exploring the effectiveness or otherwise of these bags. The results are mixed.
Battery Design and Innovation
Manufacturers are working to improve the safety of lithium batteries by incorporating features such as flame-retardant electrolytes, thermal management systems, and fail-safe mechanisms to prevent overcharging and short-circuiting. However, implementing these advancements takes time and may not entirely eliminate the risks.
Real-World Incidents and Lessons Learned
Several high-profile incidents have underscored the dangers of lithium batteries on planes:
Samsung Galaxy Note 7 Recall (2016): Samsung's flagship smartphone was banned from flights worldwide after numerous reports of faulty batteries causing fires. The incident highlighted the risks of carrying lithium batteries in personal devices.
Boeing 787 Dreamliner Battery Issues (2013): A series of battery-related incidents grounded the entire fleet of Boeing 787 Dreamliners. Investigations revealed design flaws in the aircraft's lithium-ion battery system, prompting Boeing to implement significant modifications.
UPS Flight 6 Crash (2010): This tragic incident involved a cargo plane crash caused by a lithium battery fire. It led to increased scrutiny of lithium battery shipments and stricter regulations.
These incidents are stark reminders of the potential consequences of lithium battery failures and the importance of continued vigilance.
What Passengers Can Do to Stay Safe
While regulatory and industry efforts are crucial, passengers also play a role in minimising the risks associated with lithium batteries on planes. Here are some practical tips:
“Follow Airline Guidelines” - Adhere to airline rules regarding the transport of lithium batteries, including size, quantity, and packaging limits.
“Use Reputable Brands.” To reduce the risk of defects, Purchase devices and batteries from reputable manufacturers.
"Prevent Physical Damage” - Shield batteries from physical harm, as this can result in short-circuiting or thermal runaway.
“Carry Batteries in Carry-On Luggage.” If a battery does catch fire, it is easier to detect and address it in the cabin than in the cargo hold.“Monitor Devices During Flight”: Monitor electronic devices during flight, especially if they are charging or generating heat.
The Future of Lithium Batteries in Aviation
As the demand for lithium batteries continues to grow, so does the need for innovative solutions to mitigate their risks. Researchers are investigating alternative battery technologies, such as solid-state batteries, which offer greater safety and energy density. In the meantime, collaboration among regulators, manufacturers, and airlines will be essential to ensure the safe transport of lithium batteries on aircraft.
Conclusion
The dangers of lithium batteries on planes are a pressing issue that demands attention from all stakeholders. While these batteries have transformed modern technology, their potential to cause fires, release toxic fumes, and even explode poses significant risks to aviation safety.
By understanding these risks, adhering to safety guidelines, and supporting ongoing research and innovation, we can help ensure that the benefits of lithium batteries do not come at the expense of human lives. As air travel continues to evolve, the safe handling and transport of lithium batteries must remain a top priority.