We often discuss the risks and solutions for lithium-ion batteries, but there’s another topic that relates to battery safety that you may not have considered yet. In this post, we discuss the segregation of lithium-ion batteries.
Segregation refers to the physical separation of DG from incompatible classes or divisions to control the potential for fire and other chemical hazards. While dangerous goods segregation is a topic we have written about previously, with the heightened awareness and regulations relating to lithium-ion batteries, the segregation of batteries from other dangerous goods is an important consideration for your site.
In this article, we’ll be discussing general fire risk, along with incompatible substances. This article will also offer a list of chemical segregation tips, so you can reduce your fire risk with your batteries and flammable chemicals.
Why is Segregation Important for Batteries?
Lithium-ion batteries should be segregated from other dangerous goods due to their unique fire and chemical hazard risks. Containing flammable electrolyte, these batteries can become fire or explosion risks if not handled or stored correctly.
Some important points to consider are:
Fire and Explosion Risk
Thermal runaway in lithium-ion batteries can cause violent fires or explosions, especially when batteries are damaged, overcharged, or exposed to high temperatures.
If your workplace lithium-ion battery is stored near flammable gases, flammable liquids, solids, oxidizers or other volatile chemicals, the fire could escalate dramatically, causing a chain reaction of hazardous events.
Incompatible Chemical Reactions
Some dangerous goods, such as acids, may react with battery casings or electrolyte materials if leaks occur, potentially producing toxic or flammable gases.
Batteries have a unique chemistry which can lead to incidents such as battery fires.
Fire Danger with Lithium Batteries
With the escalating number of battery fires, many workplaces are now concluding that their risk management strategies must include lithium battery management. By developing an environment that can reduce the risk of battery fires, while ensuring staff are fully trained to prevent or manage incidents, you can work towards reducing the likelihood and impact of lithium battery fires.
Tips fo Improving Battery Fire Safety
While every workplace should have an effective fire management strategy, when you’re carrying lithium-ion batteries you need to further consider the unique risks associated with these cells.
A solid fire management strategy should aim to:
- Prevent fires
- Prepare for emergencies
- Ensure safe evacuation
Your battery fire plan, incorporated into your larger fire management strategy, will involve considerations for battery fire prevention, detection, protection and response. You’ll also need to enquire all equipment, such as fire suppression, smoke detectors, alert systems, fire extinguishers, blankets and other items are present and maintained.
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Staff also require training, so they are well-equipped to inspect, handle, store, charge and dispose of these Class 9 dangerous goods in the safest possible way, as to avoid such fire incidents.
Being Proactive with Chemical Segregation
Chemical segregation is a proactive risk control that supports a safe, legal, and efficient work environment. It's a cornerstone of chemical safety programs in workplaces such as laboratories, warehouses, manufacturing plants, energy facilities and industrial sites.
All dangerous goods must be kept in a situation that separates them from other incompatible substances - and that includes Class 9 lithium-ion batteries. While segregation distances and guidance may be unique to your worksite, there are general rules that can be applied to your storage, so you can understand which substances or articles must be kept separated due to potential hazards.
What Dangerous Goods Must Be Segregated from Lithium Batteries?
As we’ve discussed, there are fire and chemical hazards that can be controlled if suitable measures are put in place. These include the segregation of lithium-ion batteries from other dangerous goods.
Below is a general list of incompatible goods, and the reasons as to why the segregation or isolation is determined. However, keep in mind that you must take a risk management approach to your workplace, as battery and dangerous goods quantities - as well as workplace tasks, hazards and other specifics - may affect your segregation distances and fire control considerations.
Incompatible due to significant reactivity – must be segregated/isolated from lithium-ion batteries:
- Class 2.1 Flammable Gases
- Class 3 Flammable Liquids & C1
- Class 4.1 Flammable Solids
- Class 4.2 Spontaneously Combustible
- Class 4.3 Dangerous When Wet
- Class 5.1 Oxidising Agents
- Class 5.2 Organic Peroxides
- Class 8 Corrosive
Incompatible with lithium-ion batteries as storage may complicate fire response due to radiant heat or reactivity issues (refer to SDS for further details):
- Class 2.2 Non-Flammable, Non-Toxic Gases
- Class 2.3 Toxic Gases
- Class 6.1 Toxic Substances
- Class 9 Miscellaneous Dangerous Goods
Generally, lithium-ion batteries (in good condition) can be stored together with other lithium-ion batteries, but we highly recommend choosing a Battery Cabinet or Outdoor Battery Store that is equipped for the amount of batteries you are working with.
These storage solutions offer an optimum environment for battery storage, including safe charging points, non-combustible charging surfaces, thermal air barriers within the sheet steel construction, cooling mechanisms and self-closing doors which further protect the workplace from battery fires within the cabinet.
REMEMBER: Always refer to your individual risk assessment, and the SDS for each of your dangerous goods to further determine suitable segregation guidelines for your goods.
Fire Prevention Strategies for Batteries
Fire prevention strategies are essential for protecting people, property, and the environment—especially in workplaces where flammable chemicals (including lithium-ion batteries) are present.
Some tips for reducing fire danger includes:
1. Eliminate or Control Ignition Sources
Ignition sources are everywhere in workplaces from welding equipment to electrical work and pilot lights. Make sure you know your sources and they are away from your batteries and other flammable materials.
No Smoking Policies: Strictly enforce no-smoking zones near flammable materials.
Isolate Ignition Sources: All types of ignition sources including powerpoints, hot surfaces, pilot lights and more.
Control Static Electricity: Use antistatic mats, grounding/bonding for containers.
Maintain Electrical Systems: Regularly inspect for damaged wiring, overloaded circuits.
Permit Hot Work: Require hot work permits for welding, grinding, or cutting.
Intrinsically Safe Equipment: Use certified equipment in hazardous areas.
IMPORTANT: Do you need support with your Hazardous Area? We provide a full range of services including Risk Assessments, Emergency Planning and Hazardous Area Classification. Get in touch today for a complete dangerous goods risk management solution.
2. Suitable Segregation & Storage of Batteries (and Other Flammable Dangerous Goods)
Careful storage can greatly reduce the risks associated with batteries and contain the fire. We recommend you choose proven battery charging cabinets (as batteries are more likely to ignite when on charge), that provide the controlled, cool and dry environment needed for safe storage.
While dedicated storage for each class or division of dangerous goods enables successful segregation, you should also allow significant distances between your battery stores and other dangerous goods. Remove any other hazards from the area including combustible materials, paperwork or clothing.
Australian-made lithium-ion battery cabinets from Storemasta that are constructed from sheet steel, provide a cool, dry environment with safe charging that's electrically certified.
3. Control the Handling of Batteries
Training staff to follow the manufacturer's instructions and ensure safe handling of cells is a crucial requirement for battery managment and fire prevention. We suggest only keep the smallest practical amount of dangerous goods (including batteries) in work areas, to reduce your risk. And ensure that all battery cabinets, handling areas and charging areas are clearly marked.
Provisions for battery training may include:
- Clear identification of battery types and risks
- Optimum conditions for the handling and storage of cells
- The correct charger for the battery
- Understanding of the risks of overcharging or overdischarging
- Awareness of the hazards associated with damaged or aged batteries
- Suitable PPE for battery handling
- Identification of warning signs of a battery fire or failure
- Emergency procedures for potential fires
4. Battery Risk Assessments and Compliance
Conduct fire risk and dangerous goods risk assessments, with the provision of your lithium-ion batteries. This will help you Identify hazards, evaluate risks, and implement controls.
Battery regulations and Standards are changing, so make sure you stay up-to-date with the latest information from Australian Standards and your local regulatory body. We also recommend staying connected with fire services who offer some of the most relevant and timely information on fire prevention and control.
5. Battery Fire Prevention
Storemasta offers a range of fire protection solutions that are tested and proven with lithium-ion battery fires. Unlike other extinguishing agents, these solutions are porous glass granules that melt to encase the heat source, therefore containing a battery fire. This innovative technology is new to the Australian market and is an excellent fire prevention control that can prevent the fire from further damaging your workplace and harming your people.
If your batteries undergo thermal runaway, they can spark fires or explosions in multiple cells. That's why Battery Safes and Charging Cases - equipped with Pyrobubbles - offer optimum protection against battery fires.
Segregation for Lithium-ion Batteries
As we know, lithium ion batteries are everywhere, and their popularity for applications continues to grow. Battery cell malfunctions, extreme heat and humidity, damaged lithium ion battery cells — as well as poor storage or handling techniques — can increase fire risk. Therefore, taking a full risk management approach to your lithium-ion batteries is an important consideration for any workplace.
By developing a safe environment for the storage and handling of your batteries — which includes segregation of your goods — you can reduce the likelihood and impact of lithium ion battery fires.
Learn more about li-ion safety precautions? You can discover more about reducing your workplace battery risks by accessing a copy of our free eBook. This easy-to-read guide discusses the most common hazards associated with workplace batteries such as lithium-ion cells and lead acid batteries. Get your copy today.
