Current Practices: Electric Vehicle and Energy Storage Systems

updated: January 2025

Lithium Ion Battery Fires and Emissions Characterization

In May 2024, Texas A&M Engineering Extension Service (TEEX), along with its research partners, conducted a series of tests to determine the contamination produced by lithium-ion (Li-ion) batteries and its impact on first responders and their personal protective equipment (PPE). Researchers also measured the effectiveness of different cleaning methods. All tests were conducted at the Southwest Research Institute (SwRI) facility in San Antonio, Texas, under the direction of Dr. Imad Khalek, Institute Engineer and Principal Investigator.

Li-ion batteries are used in electric vehicles, energy storage systems, scooters, bicycles, hoverboards and other consumer products. During testing, researchers subjected the batteries to thermal runaway by overcharge. The tests were conducted in a blast chamber where bunker gear swatches, apparatus fabric and self-contained breathing apparatus (SCBA) straps (referred to as equipment) were exposed to the byproducts of Li-ion battery fires. The tests measured 24 heavy metals and 75 semi-volatile organic compounds (SVOCs) resulting from the Li-ion battery fires.

Three separate tests were conducted:

  • Test 1 exposed bunker gear swatches and equipment to Li-ion battery thermal runaway with an analysis of the chemical and metal particulates in the gear with no cleaning performed.
  • Test 2 exposed bunker gear swatches and equipment to Li-ion battery thermal runaway and the bunker gear swatches were cleaned using traditional NFPA 1851 water-based extraction.
  • Test 3 exposed bunker gear swatches and equipment to Li-ion battery thermal runaway, and the bunker gear swatches were cleaned using a liquid carbon dioxide (CO2) process.

The tests concluded that:

  • Li-ion battery thermal runaway fires are an extreme emissions event, releasing highly toxic gases and particles that exceed the Occupational Safety and Health Administration (OSHA)-permissible exposure limits (PEL).
  • During the tests, contamination in the blast chamber was extremely high. It ranged from 12,000 to 17,000 times more than the United States Environmental Protection Agency (EPA) ambient standard of 9 μg/m³ for Particulate Matter (PM). Emissions were dominated by metallic particles and, to a lesser extent, soot.
  • High concentrations of lithium, nickel, cobalt, manganese and copper were detected during each Li-ion thermal runaway event, with lithium being the most dominant.
  • The traditional NFPA 1851 water-based cleaning of the PPE removed about 99.2% of all the metallic particles in the gear; liquid CO2 cleaning removed 99.8% of all the metallic particles.
  • Some of the SVOCs remained in the gear after water-based cleaning. Cleaning efficiencies ranged from 21% to 92%. Liquid CO2-based cleaning was highly effective, with many SVOCs being undetected in the cleaned gear.
  • Several metals, such as cobalt, manganese and lithium, remained in the gear regardless of the cleaning method used.

Upcoming Speaking Engagements

National Foam School

March 26, 2025

Texas Law Enforcement Leadership Conference, Half-Day EV Workshop

March 31, 2025

TAMU CRO Annual Conference

April 2, 2025

DoD Fire Certificate Authority, Half-Day EV Workshop

April 11, 2025

FDIC International, Half-Day EV Workshop

April 11, 2025

Texas Fire Chiefs Association

April 16, 2025

Emergency Management Symposium

May 6, 2025

2025 EHS Seminar & Industry Tradeshow

June 4, 2025

National Sports Safety and Security Conference & Exhibition

July 1, 2025

EV/Li Fire & Safety Video Series

  • How are First Responders Handling Electric Vehicle Fires?
  • What is the main difference between Internal Combustion Engines and Electric Vehicles?
  • How is an Electric Vehicle Fire Different than an Internal Combustion Engine Fire?
  • What Triggers an Electric Vehicle Fire (Thermal Runaway)?
  • Summary of Why Emergency Stop (E-stop) Buttons Should be at EV Recharging Stations
  • Raising Public Awareness Regarding Lithium-ion Batteries
  • Understanding Hazards of Lithum-ion Batteries
  • First Responder Tips for Lithium-ion Fires
  • How First Responders Treat Lithium-ion Fires
  • Lithium battery benefits
  • How Photovoltaic Energy (Solar) Could Affect First Responders
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Resources

Emergency Technical Decon

Liquid CO2 Bunker Gear Cleaning Service

Energy Security Agency (ESA)

European Environment Agency (EEA)

Report 13/2018: Electric Vehicles From Life Cycle and Circular Economy Perspectives

EV Rescue- Response Guide application

Apple Store Application: EV Rescue-Electric Vehicles (EVR)

Lithium-Ion and Energy Storage Systems Resources

Fire Safety Research Institute (FSRI)

Take Charge of Battery Safety

HazMat and Rescue Training

Lithium Ion Battery Resources

International Association of Fire Chiefs (IAFC)

Lithium-Ion and Energy Storage Systems Resources

QR Code linking to Emergency Response Guides.

National Fire Protection Agency (NFPA)

Emergency Response Guides from 35+ alternative fuel vehicle manufacturers for free download

National Transportation Safety Board (NTSB)

Report on Safety Risks to Emergency Responders from Lithium-Ion Battery Fires in Electric Vehicles

U.S. Dept. of Energy

Alternative Fuels Data Center – Electric Vehicles in Texas

U.S. Fire Administration (USFA)

Battery Fire Safety Tips