Mining vehicle manufacturers are developing lithium-ion (Li-ion) battery electric vehicles as an alternative to diesel-powered vehicles. In gassy underground mines, explosion-proof (XP) enclosures are commonly used to enclose electrical ignition sources to prevent propagation of an internal methane-air explosion to a surrounding explosive atmosphere. Li-ion batteries can create pressurized explosions within sealed enclosures due to thermal runaway (TR). NIOSH researchers measured TR pressures of nickel manganese cobalt (NMC) cathode type 18650 Li-ion cells, model MH1, as a function of free space within sealed enclosures and observed an inverse power relationship. TR pressure-rise rates, gas quantities, and temperatures were also measured. A confined NMC cell with 92.5 mL of free space produced 232 bar of pressure, far exceeding minimum pressure containment specifications for conventional XP enclosures. Approximately 287 times the cell volume of free space would be needed to reduce the TR pressure of these cells to 8.62 barg (125 psig) per U.S. Code of Federal Regulations, Title 30, Part 18. The NMC cell TR pressures were significantly higher than those measured previously for iron phosphate cathode Li-ion cells under comparable confinement conditions. 2022

Aerosols emitted by the explosion of lithium-ion batteries were characterized to assess potential exposures. The explosions were initiated by activating thermal runaway in three commercial batteries: (1) lithium nickel manganese cobalt oxide (NMC), (2) lithium iron phosphate (LFP), and (3) lithium titanate oxide (LTO). Post-explosion aerosols were collected on anodisc filters and analyzed by scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS). The SEM and EDS analyses showed that aerosol morphologies and compositions were comparable to individual grains within the original battery materials for the NMC cell, which points to the fracture and ejection of the original battery components during the explosion. In contrast, the LFP cell emitted carbonaceous cenospheres, which suggests aerosol formation by the decomposition of organics within molten microspheres. LTO explosion aerosols showed characteristics of both types of emissions. The abundance of elements from the anode, cathode, and separator in respirable aerosols underscored the need for the selection of low-toxicity battery materials due to potential exposures in the event of battery thermal runaway. Copyright © This work was authored as part of the Contributor's official duties as an Employee of the United States Government and is therefore a work of the United States Government. In accordance with 17 USC. 105, no copyright protection is available for such works under US Law.

Mining vehicle manufacturers are developing lithium-ion (Li-ion) battery electric vehicles as an alternative to diesel-powered vehicles. In gassy underground mines, explosion-proof (XP) enclosures are commonly used to enclose electrical ignition sources to prevent propagation of an internal methane (CH4) air explosion to a surrounding explosive atmosphere. Li-ion batteries can create pressurized explosions within sealed enclosures due to thermal runaway (TR). Researchers at the National Institute for Occupational Safety and Health (NIOSH) measured TR pressures of lithium iron phosphate (LFP) cells as a function of free space within sealed enclosures and observed an inverse power relationship. A well-confined cell produced 294 bar (4260 psia) of pressure during a TR, far exceeding minimum pressure containment specifications for conventional XP enclosures. Results indicate that adding enough free space surrounding LFP cells can reduce TR pressures to levels below that expected for CH4-air ignitions. Measured TR temperatures were below the minimum autoignition temperature of CH4-air.

Researchers with the National Institute for Occupational Safety and Health (NIOSH) studied the potential for lithium-ion cell thermal runaway from an internal short circuit in equipment for use in underground coal mines. In this third phase of the study, researchers compared plastic wedge crush-induced internal short circuit tests of selected lithium-ion cells within methane (CH4)-air mixtures with accelerated rate calorimetry tests of similar cells. Plastic wedge crush test results with metal oxide lithium-ion cells extracted from intrinsically safe evaluated equipment were mixed, with one cell model igniting the chamber atmosphere while another cell model did not. The two cells models exhibited different internal short circuit behaviors. A lithium iron phosphate (LiFePO4) cell model was tolerant to crush-induced internal short circuits within CH4-air, tested under manufacturer recommended charging conditions. Accelerating rate calorimetry tests with similar cells within a nitrogen purged 353-mL chamber produced ignitions that exceeded explosion proof and flameproof enclosure minimum internal pressure design criteria. Ignition pressures within a 20-L chamber with 6.5% CH4-air were relatively low, with much larger head space volume and less adiabatic test conditions. The literature indicates that sizeable lithium thionyl chloride (LiSOCl2) primary (non rechargeable) cell ignitions can be especially violent and toxic. Because ignition of an explosive atmosphere is expected within explosion proof or flameproof enclosures, there is a need to consider the potential for an internal explosive atmosphere ignition in combination with a lithium or lithium-ion battery thermal runaway process, and the resulting effects on the enclosure.

National Institute for Occupational Safety and Health researchers are studying the potential for Li-ion-battery thermal runaway from an internal short circuit in equipment approved as permissible for use in underground coal mines. Researchers used a plastic wedge to induce internal short circuits for thermal runaway susceptibility evaluation purposes, which proved to be a more severe test than the flat plate method for selected Li-ion cells. Researchers conducted cell crush tests within a 20-L chamber filled with 6.5 % CH4-air to simulate the mining hazard. Results indicate that LG Chem ICR18650S2 LiCoO2 cells pose a CH4 explosion hazard from a cell internal short circuit. Under specified test conditions, A123 Systems 26650 LiFePO4 cells were safer than the LG Chem ICR18650S2 LiCoO2 cells at a conservative statistical significance level.