Page 14 - Process Safety and the Energy Transition: Battery Technology

In addition to the batteries and energy storage systems deployed and in demonstration, there
are also technologies in development. Of note are hydrogen systems and the sodium-ion battery.
Hydrogen systems require storage tanks or geologic formations, and synthetic natural gas where
excess electricity is converted to synthetic methane for later use. The sodium-ion battery uses
sodium, which is abundant and commercially available, and use non-flammable or low-volatility
electrolytes, which significantly reduce the risk of thermal runaway compared to lithium-ion
systems. Additionally, these batteries can be fully discharged (enabling safer transportation).
These characteristics position sodium-ion batteries as a safer alternative to Li-ion technologies.
Although they are less energy dense and thus take more space, sodium-ion seem to be a viable
technology for grid-level energy storage where space allows. (Sandia, 2025) (DOE, 2023)

As these, and any, new battery technologies are developed, process safety methods should
be applied to aid in identifying potential hazards and managing risks before deployment.

Process safety risks associated with batteries extend beyond the energy generation phase.
There may be risks across the lifecycle that should be considered, for example, in the acquisition
of materials (e.g. mining), manufacturing, transport, recycling, and disposal of batteries. All
hazards and risks should be considered. The European Union regulation EU 2023/1542 addresses
batteries and sustainability across their lifecycle. (EU, 2025) (European Parliment, 2022)

What: Fire
Facility: Critical Mineral Recovery Recycling Facility – A facility that retrieves metals
and minerals from electric vehicle vehicles and consumer-grade lithium-
ion batteries for use in manufacturing new batteries
Where: Fredericktown, Missouri
When: October 2024
Impact: Evacuations and shelter-in-place orders were issued
Note: The fire occurred despite a sophisticated fire detection and suppression
system.
(MI, 2024)

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Process Safety and the Energy Transition: Battery Technology
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