New research calls for multi-pronged approach to lithium-ion battery safety

Lithium-ion batteries are integral to a wide range of devices and machines across industries, resulting in a significant volume of shipments. However, transporting lithium-ion batteries on ships poses significant risks, including fire and explosion hazards.

“Thermal runaway, where one failing cell can cause adjacent cells to fail, can lead to intense fires. Improper handling and packaging can compound these risks, and the limited firefighting resources on ships make controlling such fires challenging,” explains Mike Barry, Risk Specialist at If.

 “Additionally, fires involving lithium-ion batteries can release toxic gases, increasing risks to the crew and posing environmental hazards. Lately, we have seen a higher number of fires onboard ships due to improperly declared containers as well as EV automobiles on Roll-on/Roll Off (RoRo) vessels. It is of utmost importance that shippers know what they are transporting and that they advise shipping companies accordingly. Even limited quantities of lithium-ion batteries can pose risks if not correctly reported,” says Barry.  

A lithium-ion battery fire took place on the April 16, 2025, when a blaze broke out on the RoRo ship MV Delphine, while it was berthed at logistics solutions provider CLdN’s terminal in Zeebrugge, Belgium. The incident, which started on a cargo deck carrying approximately 60 electric vehicles (EV) and 40 conventional cars, caused significant damage.

Recent reports state that the fire did not originate in an EV, however, electric vehicles were involved as it progressed. The fire triggered the vessel’s CO2 fire suppression system, and local firefighters quickly evacuated the crew. Four tugboats equipped with water cannons were deployed to cool the ship's hull. Despite the intense heat and challenges brought by burning lithium-ion batteries, the fire was extinguished using a combination of CO2, nitrogen, and external cooling.

Barry notes, "The latest industry guidelines, from Vehicle Carrier Safety Forum, (1) recommend operators respond by promptly evacuating, shutting down ventilation, and starting CO2 flooding very early in the firefighting process. Putting out fire using CO2, nitrogen, and external cooling is effective in this scenario because CO2 and nitrogen displace the oxygen that is essential for combustion. External cooling helps reduce the temperature of the burning material, preventing re-ignition.” 

 

Safety considerations
The use of lithium-ion batteries presents unique risks due to several factors, including the following (1):

• Thermal runaway is a self-sustaining, uncontrolled increase in temperature within a battery cell, leading to fire or explosion. A battery cell that is damaged or exposed to intense heat can trigger thermal runaway. 
• Confined spaces and enclosed compartments where flammable gases can accumulate from the batteries, and the gas buildup can lead to explosions if ignited.
• Fire suppression challenges arise when putting out BESS fires, as the unique nature of lithium-ion batteries can present significant difficulties. Traditional firefighting methods may not work, and specialised solutions such as water-based or gaseous suppression systems are needed to manage the fire and reduce explosion risks. These complexities make fire suppression a demanding task that requires careful planning and advanced technology.

COMBAT research findings

The COMBAT study (2) highlights the importance of using multiple strategies to effectively manage the risks of BESS explosions.

Here is some mitigation strategies presented in the study:

• Ventilation: Helps reduce gas concentration but does not eliminate explosion risks. Different levels of ventilation – basic, preventive, casualty – are recommended.
• Deflagration panels: These are designed to lessen the impact of explosions, with effectiveness dependent on covering sufficient surface area.
• Fire suppression systems: Water-based systems provide long-term cooling and can reduce explosion pressure. Gaseous systems can help if gas concentration is maintained at a sufficiently high level.

Advancements in lithium-ion batteries and BESS are paving the way for a more sustainable and resilient energy future. Nevertheless, as we embrace these technologies, it is crucial to remain vigilant about the associated risks. Ongoing research, such as the COMBAT project, highlights the importance of understanding and mitigating the dangers of lithium-ion batteries, especially in confined spaces.

Investing in research and developing comprehensive safety strategies can optimise the advantages of lithium-ion batteries while controlling potential hazards. As we move forward, continued collaboration and innovation will be the key to safely integrating these technologies across industries and in our everyday lives.