Why Lithium Batteries Pose a Serious Threat in Aviation Safety?

Lithium batteries are today’s power source of choice. As we become ever more reliant on Portable Electronic Devices (PEDs) to provide at your fingertips information, entertainment and communication, then so increases the demand for more powerful, yet lighter, sources of power.

Hundreds of millions of Lithium batteries or equipment with Lithium batteries are carried on aircraft annually. These can be as part of passengers carry-on items, as aircraft (e.g. Portable IFE, defibrillators) or aircrew equipment (such as Electronic Flight Bags). They can be shipped as cargo in battery form or within other purchased items to support the demand for “just in time deliveries”, or indeed as power supply for aircraft equipment. Lithium batteries are becoming continually more common place in the aircraft environment.

But the introduction of Lithium batteries included some highly visible cases of cell phones or laptops self-igniting and burning. Likewise, several events have occurred on aircraft, ranging from localized and limited fires to large, uncontrolled in-flight fires resulting in hull losses and fatalities.

The air industry has become more aware of the specific characteristics of Lithium batteries and the associated risks can now be mitigated. Procedures have been developed to address the risks for Lithium batteries being part of the aircraft design, those belonging to passengers or crews carry-on items, or indeed procedures linked to the shipping of Lithium batteries as cargo.

Lithium Batteries

Lithium batteries power many of the electronic devices we use daily—smartphones, laptops, tablets, cameras, and more. While efficient and rechargeable, these batteries can pose serious safety risks when damaged, short-circuited, or overheated, as they may catch fire.

To ensure safety during air travel, passengers should always carry portable electronic devices (PEDs)—such as phones, cameras, and laptops—in their hand baggage (carry-on), not in checked baggage. Under normal conditions, these devices can be used on board for activities like reading, working, watching movies, or listening to music. Many airlines also allow limited use of mobile phones (e.g., playing games), but remember: PEDs may interfere with aircraft systems. To avoid issues, airlines require all devices to be switched to airplane mode throughout the flight.

If you must place a device in your checked baggage—which is not recommended—make sure it is completely switched off and cannot be accidentally activated. However, spare batteries and power banks are strictly prohibited in checked baggage. These items must be packed in your carry-on and individually protected to prevent short-circuits. This includes items like e-cigarettes, which must also be carried in hand luggage only.

Important safety reminders:

• Spare batteries and power banks must not be recharged while on board.

• Power banks must not be connected to devices during the flight.

• All batteries must comply with airline restrictions on watt-hour (Wh) limits.

E-cigarettes

Electronic cigarettes (e-cigarettes) contain a battery and a heating element that vaporizes a liquid vapour to simulate tabacco smoking.

Several incidents were reported to the International Civil Aviation Organization (ICAO) involving e-cigarettes overheating resulting in a fire in checked baggage. For this reason, these devices can only be carried in the cabin, and it is forbidden to recharge them while on board the aircraft.

Personal transportation devices

Small lithium battery powered personal transportation devices, also known as hoverboards, self balancing devices or gravity boards, were one of the most sold devices recently. However, there have been incidents where these items or their batteries overheated, caught fire and even exploded.

Passengers are not allowed to carry these batteries in their checked bag, as batteries have a rating of 100 Wh or more. Because of the high risk posed by these devices, many airlines have decided to additionally restrict their transport in the cabin. It is therefore safer to leave these items at home when flying. 

Why do lithium-ion batteries catch fire?

Lithium-ion battery cells combine a flammable electrolyte with significant stored energy, and if a lithium-ion battery cell creates more heat than it can effectively disperse, it can lead to a rapid uncontrolled release of heat energy, known as ‘thermal runaway’, that can result in a fire or explosion.

Thermal runaway can be caused by a number reasons, including an internal short circuit due to manufacturing defects, ’lithium plating’ (formation of metallic lithium on an anode surface within a battery cell), or mechanical damage (e.g. piercing, dropping). Other possible causes of thermal runaway are exposure to heat from an external source or overcharging/over-discharging.

Thermal runaway can result in the ejection of a range of flammable and toxic gases from battery casings. The flammable gases generated often ignite immediately, but may also spread out unignited, until an external ignition source is encountered, resulting in an explosion.

Lithium-ion battery fires generate their own oxygen and can be very difficult to extinguish. Specialist Aqueous Vermiculite Dispersion (AVD) fire extinguishers may be an option for small incipient fires, where extinguishing media can be applied directly to the cells of a battery, providing a combination of cooling and oxygen depletion, but these fires are very often only controlled and extinguished when the Fire & Rescue Service deliver copious amounts of water to the burning materials.

More Resource

Lithium Batteries - More Practical Information

Lithium Batteries; Safe to Fly?

Why Do Lithium-Ion Batteries Catches Fire?

Dangerous Good| EASA