Page 17 - Process Safety and the Energy Transition: Battery Technology

The battery failure event can include internal short circuits, thermal pressurization, and venting
of flammable gases such as hydrogen, toxic gases, and fine metallic particulates. These emissions
pose significant risks of fire, explosion, and exposure, particularly in confined or poorly ventilated
environments. Effective risk mitigation requires robust containment design, gas detection systems,
and adherence to thermal and electrical protection protocols. These gases can spontaneously
ignite as seen in Figure 9. The resulting fire creates more heat which causes further decomposition
reactions, generating more gases, more venting and more burning. A thermal runaway occurs
when this cycle is self-perpetuating. The thermal runaway can result in fire and propagate to
adjacent batteries or exposures, greatly expanding the scale of the event.

The quality and condition of the battery are
critical factors in the risk of failure.

Figure 9 – Lithium-ion battery fire (FAA, 2025)

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Process Safety and the Energy Transition: Battery Technology
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