Regular maintenance and inspections are vital to ensure all safety equipment is functional and reliable for a safer teaching/learning environment. However, a relatively alarming number of explosions and fires have occurred related to storage, use, and disposal of Li-ion and Li-polymer battery powered equipment (Li-based power supplies) such as cell phones, computers, and other electronic equipment often found and used in school science, technology/engineering, and art instructional spaces. It is important to understand that Li-based power supplies are everywhere in your schools, from the students and their backpacks to the classrooms, maintenance sheds, and storage rooms. Few, if any, schools have an accurate inventory of the Li-powered devices they have in storage. Knowing how to prevent a Li-based power supply failure through proper use, storage, charging, and disposal, as well as what to do if one occurs, is of paramount importance to your students, colleagues, schools, and yourself.

Recent examples of Li-based battery fires and explosions highlight ongoing safety concerns. Here are a few notable incidents.

1. Electric Vehicles (EVs)
•    Tesla Fires. Fires have been reported with several Tesla models, often linked to battery malfunctions after crashes or severe impacts. For instance, incidents in 2021 involved vehicles catching fire post-collision, prompting investigations into battery safety protocols.

2. Consumer Electronics
•    Samsung Galaxy Note 7. Although it happened several years ago (2016), this incident is often cited due to its impact. The phones were recalled after multiple reports of battery fires caused by manufacturing defects, leading to a major safety overhaul in the industry.
•    Laptop Batteries. In 2021, Dell recalled certain laptop batteries due to overheating risks, which had led to several fire incidents. The recall affected specific models manufactured between 2017 and 2020.

3. Power Tools
•    Cordless Tool Fires. In 2023, several incidents involving cordless power tools catching fire due to faulty Li-based batteries were reported. These incidents often involved overheating during use or charging.

4. House Fires
•    Battery Charging Fires. There have been various reports in recent years of house fires started by Li-based power supplies left charging overnight. Some incidents involved chargers that failed, leading to overheating and ignition of nearby materials.

These examples underline the importance of proper handling, charging, storage, and disposal practices for Li-based power supplies to mitigate risks associated with their use.

Li-based power supplies, while widely used and efficient, come with several potential dangers. Here are the key hazards and risks associated with their use.

1. Fire and Explosion
•    Thermal Runaway. Overcharging, short circuits, or physical damage can cause a rapid increase in temperature, leading to fires or explosions. Do not attempt to extinguish a Li-powered device that is in thermal runaway.
•    Flammable Electrolytes. The organic solvents used in Li-based power supplies are flammable and can ignite under certain conditions, especially when damaged.
•    Oxygen Generation. Li-based power supplies generate their own oxygen during thermal runaway. The fire extinguishing and suppression systems found in your classroom are not enough to extinguish them.

2. Chemical Hazards
•    Toxic Materials. Li-based power supplies contain hazardous materials such as lithium, cobalt, and nickel, which can be harmful if released.
•    Leakage. Damaged batteries can leak harmful chemicals, posing risks to health and the environment.
•    Gases. Li-based fires emit tremendous amounts of highly toxic chemicals that can do severe short-term or long-term damage. Do not approach without the proper Personal Protective Equipment, which includes a Self-Contained Breathing Apparatus.

3. Physical Damage
•    Swelling and Bulging. Damage can lead to battery swelling, which indicates internal failure and increases the risk of rupture. Do not attempt to fix a swelling battery. Follow your school’s protocol for this situation. If your school does not have a protocol, or you have not been trained in the protocol, remove everyone from the room and contact the building administration.
•    Punctures and Cracks. Physical impact can compromise battery integrity, leading to potential hazards. Never use a battery that is deformed or punctured. 
•    Manufacturing Defects. Inspect all Li-based power supplies–powered devices when received. Do not use or charge a device that was damaged in manufacturing or transport.

4. Overcharging
•    Battery Degradation. Overcharging reduces battery lifespan and efficiency.
•    Safety Mechanism Failure. If protection circuits fail, it can lead to dangerous situations like overheating or fires when overcharged.
•    Heat. Overcharging a Li-based power supplies–powered device can cause it to overheat, which can lead to thermal runaway. In addition, never charge one unattended.

5. Environmental Impact
•    Improper Disposal. Li-based power supplies will cause soil and water contamination if not disposed of correctly. They also pose a danger to our sanitation and waste management professionals.
•    Resource Extraction. Mining for materials used in batteries has significant environmental impacts. Just recently, a Lithium refinement factory in Missouri caught on fire, causing extensive environmental damage.

6. Electrical Hazards
•    Short Circuits. Incorrect connections can cause short circuits, leading to overheating and potential fire.
•    Static Electricity. Mishandling can generate static charges that may cause discharges, especially in sensitive applications. Consult your Manufacturer’s Recommendation Handbook for more information.

7. Battery Aging
•    Capacity Loss. Over time, Li-based power supplies lose capacity, which can lead to unexpected failures in devices, particularly in critical applications.

8. User Misunderstanding
•    Misuse. Lack of understanding about charging protocols and safety can lead to improper usage, increasing risk. You must consult the manufacturer’s handbook before storing, charging, using, or disposing of the device.

By being aware of these dangers and taking appropriate precautions, you can safely use Li-based batteries while minimizing potential risks.

When using Li-based power supplies, following safety protocols is crucial to minimize risks like fire, explosion, and chemical exposure. Here are key safety guidelines.

1.    Storage

•    Cool, Dry Environment. Store batteries at room temperature away from direct sunlight and moisture.
•    Avoid Extreme Temperatures. Keep batteries between 15°C to 35°C (59°F to 95°F). (Lithium Battery Temperature Ranges: A Complete Overview, n.d.)
•    Avoid exposure to temperatures above 54.5°C (130°F) or below -20°C (-4°F) . (Senior 2023)
•    These values can vary from device to device. Find the acceptable temperature range in the Manufacturer’s Recommendation Handbook.
•    Use Original Packaging. Store batteries in their original packaging or in insulated cases to prevent short circuits. Follow the Manufacturer’s Recommendation Handbook.

2.    Handling
•    Avoid Physical Damage. Do not drop or puncture batteries, as this can lead to internal damage and potential hazards. If you do drop a battery, inspect for any signs of failure before charging. If you puncture the battery, follow your school’s protocols. You must be trained regularly on your school’s protocols. If you have not been trained, evacuate the room or building, depending on whether the battery is jetting smoke or flames, and contact the proper administrators. If the battery is jetting smoke or flames, evacuate and pull the fire alarm. Don’t attempt to fix or alter the battery.
•    Use Proper Chargers. Only use chargers that are compatible with the specific battery type to avoid overcharging and overheating. Only use third-party charges if they are recommended in the Manufacturer’s Recommendation Handbook. Only use those exact brands and model numbers referenced.
•    Inspect Regularly. Check for signs of swelling, leakage, or corrosion. If any are present, dispose of the battery properly.

3.    Charging
•    Monitor Charging. Never leave charging batteries unattended. Charge in a safe, open area away from flammable materials.
•    Follow Manufacturer Guidelines. Adhere to recommended charging times and procedures from the manufacturer. Consult the Manufacturer’s Recommendation Handbook.
•    Avoid Overcharging. It is important to make sure you unplug the devices when they are done charging. Do not rely on the built-in cutoff features.

4.    Disposal
•    Recycle Properly. Do not throw Li-based power supplies in regular trash. Use designated recycling programs to ensure safe disposal.
•    Check Local Regulations. Follow local laws regarding battery disposal, as many regions have specific guidelines.

5.    Emergency Response
•    Know the Risks. Be aware of the potential for fire or explosion if a battery is damaged or improperly used. Consult the Manufacturer’s Recommendation Handbook.
•    Fire Extinguisher. ABC fire extinguishers are largely ineffective when battling Li-based fires. Class D fire extinguishers may work in some situations, depending on the Li-ion or polymer used in the battery. Do not rely on them as a means of protection from  the Li-based power supplies in your schools. Follow the manufacturer’s recommendations regarding fire suppression systems. If you have not been trained to use the fire extinguisher and you do not have a self-contained breathing apparatus, do not attempt to extinguish a Li-based power supplies fire.
•    Follow First Aid Protocols. In case of chemical exposure, flush the area with water and seek medical attention if necessary. Do not attempt any further first aid unless you have been trained.
•    Protocols. Have protocols in place for identifying defects or failures in Li-based power supplies and what to do in each scenario. You must be trained on what to do, which in most cases requires that you exit the failure and communicate the issue, including activating the fire alarm when warranted.

Summary
Both Li-ion and Li-polymer batteries have advantages in the academic setting. However, they both have risks that must be addressed. The best way to address the hazards is to become familiar with the Manufacturer’s Recommendation Handbook and train students and staff on what to do if a Li-ion or Li-Poly battery fail occurs. Without knowledge and training, it is impossible to keep your students safer in a Li-ion/Li-polymer educational setting.

By adhering to these protocols, in addition to the training you should receive or provide, you can significantly reduce the risks associated with using Li-ion or Li-Poly batteries for a safer teaching/learning worksite.

Submit questions regarding health and safety issues in all laboratory instructional spaces to Ken Roy at safersci@gmail.com. Follow Ken Roy on X: @drroysafersci. You can also follow Dr. Roy on LinkedIn at https://www.linkedin.com/in/dr-ken-roy-07218713/.

Safety Blog Acknowledgement

NSTA Chief Safety Blogger Dr. Ken Roy wishes to sincerely thank nationally recognized District Supervisor of Science Kevin S. Doyle, Ed. D., Morris Hills Regional District, Rockaway, New Jersey (kdoyle@mhrd.org) for his professional review of and contributions to this commentary. You can follow Kevin on LinkedIn at Kevin S Doyle, Ed.D.

Resources
NSTA Web Seminar. 2024. FA24: Catching up and charging ahead: Safely using li-ion batteries in our school classrooms/laboratories. https://my.nsta.org/resource/132224.

UFine Blog. 2024. Lithium battery temperature ranges: A complete overview. www.ufinebattery.com/blog/lithium-battery-temperature-range-everything-you-need-to-know/#:~:text=Lithium%20batteries%20work%20best%20between,F)%2C%20harming%20battery%20health.

Senior, R. 2023. July 14. Ideal operating temperatures for lithium batteries. Fortress Power. www.fortresspower.com/ideal-operating-temperatures-for-
lithium-batteries/.