Preventing EV battery fires: Essential solutions you need to know
Just as EVs are on the rise, so too are EV fires. In the two years leading up to 2024, fires involving electric vehicles jumped by 77% in the UK. Just last year, 232 incidents were recorded, and this figure is set to take off with the upcoming ban on new ICE cars.
This trend shows us two things. Firstly, there are some inherent risks with lithium-ion battery technology (though that’s not the same as saying the risks are higher than with combustion engines). Secondly, because of this rapid migration towards EVs, we are not yet fully used to this different type of risk, in which the chemical reaction is notoriously hard to extinguish – best practices are yet to mature fully.
Understanding the regulation
For EV operators, the regulatory for lithium-ion fire safety solutions are still catching up to meet this growing risk. A proposed Lithium-ion Battery Safety Bill has signalled a move towards tighter oversight, certainly, as it will mandate stricter safety standards for devices along with formalising disposal guidelines.
Specific legislation is still developing, but the Health and Safety Executive (HSE) provides some guidance on risk assessment, safe charging protocols, and of course, emergency preparedness for all workplaces handling EVs. EV fire safety products are needed, though operators can consult with established suppliers to help fully grasp the changing regulations.
Technical standards aren’t up for debate, so here are some of the most important ones:
- BS EN 50604-1: Specifies safety requirements for light EV batteries
- PAS 7061: Provides a code of practice for the safe and environmentally conscious handling of end-of-life or damaged batteries.
Proactive prevention strategies for EV operators
We can split prevention strategies into three main areas: battery management, charging, and safe storage.
Battery Management Systems (BMS)
The Battery Management System is going to play the most central role in proactive fire prevention. Its role includes monitoring, but it also actively prevents the conditions that precipitate thermal runaway. It does this by continuously balancing cell voltages and managing state-of-charge. So in the end, temperature gradients across the pack are monitored, meaning that a competent BMS can spot and interrupt hazardous events like overcharging. For operators, BMS is essentially the first line of defence and is important to maintain its efficacy.
Charging best practices
Compliant charging is super important. This isn’t a catch-all rule for charging, but instead an insistence on operators using only the manufacturer-approved charging equipment rated for the specific vehicle. Of course though, using damaged cables or non-compliant connectors has risks that can be avoided, and charging should only take place in well-ventilated areas that are clear of combustible materials. This will help reduce the likelihood of off-gassing or thermal events. It’s also wise to not keep EVs connected to a charger for a long time after they’re fully charged as this can stress the battery system.
Safe storage and handling
stresses the need to treat lithium-ion battery storage with the same care as chemical storage. While battery technology is improving, they still need to be stored in cool and dry place that has good ventilation (between 5°C and 20°C is ideal). In commercial settings, its storage must be clearly marked with appropriate fire suppression systems around it. Documented inspections should be very regular as these will help identify early signs of battery degradation. For example, this might be minute swelling of the casing or a small leakage.
The Leicester storage fire
The fire at a Leicester storage facility in early 2024 was caused by improperly stored electric scooter batteries. The event serves as a useful warning to other operations about the dangers of batteries. It showed a few different failures in safety protocol, actually, with the first being a lack of designated, segregated storage for lithium-ion batteries. This meant they were kept in close proximity, and this creates the conditions for a cascading thermal runaway event.
Secondly, the facility lacked specialised fire suppression equipment. Fire extinguishers for EV charging and other batteries must be specialised and designed to handle the unique chemistry of a Class B fire.
Emergency response
EV battery fire prevention isn’t enough, it’s also about planning an emergency response. The difficulty is that they burn at extreme temperatures, often above 1000°C, meaning it can require up to ten times more water to suppress than a traditional vehicle fire. Having the correct equipment and protocols isn’t just necessary, but it’s to some extent bespoke to your operational set-up. And, because it’s an industry and science in its infancy, consultation is recommended.
A proactive stance on EV safety
Lithium-ion fire safety solutions begin with solid and proactive prevention. It is a commitment that requires deep understanding and staying up to date with any changing best practices and regulations. It’s not just a matter of getting fined, but life or death, and the proactive protocols are a part of the rising cost of any business dealing with batteries.
