How to Handle Lithium-ion Battery Recycling Fires

Let’s discuss fires during lithium-ion battery recycling. Fires are inevitable in this process—it is not about if they will occur but when. Handling thermal events is a constant challenge when designing and assembling recycling plants.

Key Cause of Fires

Aluminum: Surprisingly, aluminum is the leading cause of fires. While the flammable solvent in batteries is often blamed, most recycled batteries are already discharged or contain minimal stored energy, lowering their fire risk.

A Real-Life Example

A customer of ours who shreds aluminum experienced a severe incident when an aluminum screened door fell into their hammer-mill shredder. This created a blockage between the hammer mill rotor and the grate, causing aluminum dust to accumulate, overheat, and lead to a thermite reaction. The reaction resulted in an explosion that blew the shredder’s top off and punctured the roof of the building. This incident highlights the importance of proper monitoring and risk management when processing aluminum-containing cathode.

The Battery Recycling Process and It’s Risks

1. For Production Scrap:
   • Production scrap (jelly rolls, cathodes, and anodes from battery manufacturing) pose a lower fire risk because they do not contain solvents.
   • These materials can often be processed dry. However, cathodes with aluminum may require cooling or processing in a nitrogen or oxygen-depleted environment to prevent thermal events.
2. For Post-Consumer Batteries:
   • Batteries from electric vehicles or bicycles are more prone to fires because they contain liquid electrolytes. Piercing these batteries during shredding can cause explosions or thermal events.
   • These batteries are best processed in wet environments, oxygen-depleted environments, or a combination of both.

Mitigating These Fire Risks

1. Mitigating Risks for Production Scrap:
   • Monitor and control temperatures to prevent thermal runaway. If critical temperatures are reached, fires are inevitable.
   • Avoid processing cathodes in isolation without proper cooling or oxygen-depleted systems.
2. Mitigating Risks for Post-Consumer Batteries:
   • Discharge batteries as much as possible before processing to minimize risks.
   • Mitigate flammable electrolytes by diluting them or using low-oxygen environments.

Final Thoughts

There is no universal solution for recycling all types of batteries—systems must be tailored to the material being processed. Fires and explosions are significant risks in the battery recycling industry, and it is crucial to work with experts who understand these dangers and can provide effective thermal management strategies.

If you would like to discuss your specific needs, please reach out to us. Let’s work together to keep your employees and workplace safe.