Preventing Lithium-ion Battery Fires: Bridging Belgium’s Legislative Gaps

Lithium-ion batteries have become the primary power source for a wide range of electronic devices, from small gadgets like e-cigarettes and smartphones to larger systems like micromobility devices and electric vehicles (EVs). And although lithium-ion batteries offer many benefits, they also pose significant hazards, especially in the recycling industry.

As the number of small and large lithium-ion batteries (e.g., EV batteries) in circulation increases, so do the risks of fire and explosion if not properly handled during recycling. Under certain circumstances, these batteries can fail and go into thermal runaway, which can result in explosions, toxic gas emissions and flames. Complicating the issue is that traditional fire suppression methods, such as water and sprinklers, have limited effectiveness in combating fires caused by these batteries.

While various groups in Belgium are working on developing guidance and best practices to mitigate these risks more effectively, regulations to help prevent lithium-ion battery fires in industrial storage and recycling facilities need to be further developed.

Li-ion Battery Risks in the Recycling Industry

Worldwide, lithium-ion (Li-ion) batteries have been increasingly linked to fires and explosions, causing significant damage and injury. UK fire services, for example, reported a 46% increase in fires associated with lithium-ion batteries in 2023, with at least 190 people injured and 10 killed since 2020.

The waste management and recycling industries have seen an increasing number of fires linked to Li-ion batteries in recent years. A 2021 report from Eunomia Research and Consulting, published with the assistance of the Environmental Services Association (ESA), revealed that an estimated 201 waste fires are caused by lithium-ion batteries every year in the UK, costing the country over £158 million annually. Furthermore, a European study suggests that 78 million lithium-ion batteries could be discarded daily worldwide by 2025.

Li-ion batteries can easily mix with other recyclable materials and become punctured, crushed or physically damaged during mechanical sorting and processing, leading to fires and explosions. Similarly, exposure to high temperatures can degrade battery components. Physical damage may cause thermal runaway, a condition where an increase in temperature causes further temperature increases, leading to a self-sustaining reaction. Manufacturing defects can also lead to internal short circuits, which can cause the battery to heat up rapidly. Both scenarios can result in fire, explosion and release of toxic gases.

Bridging the Gaps in Belgian Legislation

Belgium’s Royal Decree of 7 July 1994 establishes the legislative framework for the prevention of fire and explosions in buildings. Since its implementation, several updates have been made to the legislation to facilitate the changing construction environment. In 2009, Appendix 6 was added to address the design, construction and furnishing of industrial buildings, which, as defined by the legislation, consisted of buildings intended for a range of commercial processing or storage activities (e.g., furniture assembly, raw material storage, animal keeping).

Appendix 6, however, does not address production facilities nor does it provide specifications for the storage of hazardous goods (e.g., toxic, highly flammable, explosive). For production buildings, often it would result in a derogation filed at the Ministry of Interior and would come with favourable advice from the Authority Having Jurisdiction (AHJ).

To bridge the gap between the legislative framework and the real-life risks, the Flanders Fire Brigade produced guidelines and uses them to address industrial warehouses that store hazardous goods. Currently, this is only active in Flanders and doesn’t cover the risk of lithium-ion battery fires and explosions in storage and recycling facilities.

Different stakeholders are currently working on developing legislative frameworks and guidelines for these industrial buildings. The hope is the next revision of the Belgian legislative framework is updated to cover lithium-ion battery fire and explosion risks. In the meantime, fire consultancies like Jensen Hughes are bridging the gap to address these risks and hazards.

At Jensen Hughes, we currently approach the problem through a risk analysis focused on:

• Improving storage and transportation through the use of specific containers/racks for battery storage, temperature control measures and continuous monitoring.
• Investigating the correct continuous monitoring systems to detect potential risks early, ensuring quick response and prevention of severe incidents.
• Enhancing safety protocols and procedures for handling damaged or end-of-life batteries in close collaboration with the client.
• Protecting people and property with an effective system that results in the best possible outcomes in case of fire.

Mitigating Fire Risks in Recycling Facilities

Safer manufacturing processes should include rigorous quality control measures to detect and eliminate defects that could lead to internal short circuits. Robust testing under various conditions should also be conducted to ensure batteries can withstand physical impacts and temperature fluctuations without failing. For safe storage and transportation, maintaining controlled environments to prevent overheating and using fire-resistant and impact-resistant packaging materials to safeguard batteries from physical damage is essential.

Safer manufacturing processes should include rigorous quality control measures to detect and eliminate defects that could lead to internal short circuits. Robust testing under various conditions should also be conducted to ensure batteries can withstand physical impacts and temperature fluctuations without failing. For safe storage and transportation, maintaining controlled environments to prevent overheating and using fire-resistant and impact-resistant packaging materials to safeguard batteries from physical damage is essential.

Advanced fire suppression systems should be designed specifically to combat Li-ion battery fires, with early detection systems that can identify the onset of thermal runaway and promptly activate alarm systems and required fire safety protocols. In recycling facility design, specifically, automated systems can safely sort and handle Li-ion batteries and reduce the risk of accidental damage during processing. Dedicated recycling units with enhanced safety measures, such as fireproof containment areas and specialized disassembly tools, can further mitigate risks.

Address Li-ion Risks and Protect Your Facility

Prioritizing your facility’s safety, efficiency, and environmental protection is crucial. Using our extensive expertise in Li-ion battery recycling, Jensen Hughes can help integrate solutions within existing waste management systems that address the specific risks of Li-ion batteries. We have worked on multiple projects for local facilities and international recycling plants worldwide and developed the concept and basic design of one of Europe's largest Li-ion recycling facilities. Our team also investigates Li-ion battery-related fires in the recycling industry, providing valuable insights for improving safety standards.

Discover how our expert consultants go above and beyond to find the best solutions to help create a safe environment across building and industrial facilities.