Lithium-Ion Battery Fires on Airplanes: Why Passenger Awareness and Proper Device Handling are Crucial

Lithium-ion batteries, ubiquitous in today’s electronic devices from smartphones to vapes, pose a significant threat when malfunctioning aboard aircraft. A recent incident involving Delta Air Lines Flight 1334 exemplifies this risk. The flight, traveling from Atlanta to Fort Lauderdale, was forced to make an emergency landing in Fort Meyers due to smoke and flames emanating from a passenger’s carry-on bag, containing a personal lithium-ion battery pack.

At the Federal Aviation Administration’s (FAA) research facility in Atlantic City, New Jersey, fire safety engineers investigate and demonstrate the potentially devastating consequences of lithium battery malfunctions. When subjected to thermal runaway – an uncontrolled overheating – these batteries can release molten electrolyte, flames, smoke, and toxic gases.

To illustrate this danger, the FAA conducted a demonstration for CNN inside their research hangar. A rechargeable consumer battery pack, similar to those used for laptops or cell phones, was placed in a seatback pocket and heated beyond 300 degrees Fahrenheit to simulate thermal runaway. The result was an immediate eruption of sparks and flames, scorching nearby seats and producing thick smoke.

“Lithium batteries can undergo what’s known as thermal runaway,” explained Fire Safety Branch Manager Robert Ochs. “Suddenly, it’ll start to short circuit … It will heat up until the structure of the battery itself fails. At that point, it can eject molten electrolyte and flames and smoke and toxic gas.”

These thermal runaways are challenging to combat. The FAA advises flight attendants to initially use a halon fire extinguisher – standard equipment on planes – but acknowledges that this may not be sufficient. In the test performed for CNN, the flames resurged almost instantly after initial extinguishment with a halon fire extinguisher.

Additional measures, such as pouring water or non-alcoholic liquids onto the device, may help to suppress the flames temporarily but do not guarantee complete extinction.

The use of lithium-ion batteries by passengers is on the rise, with the average passenger now carrying four such devices on board. Safety organization UL Standards and Engagement reports that incidents involving these batteries, while still rare, are increasing, with as many as two per week occurring either on planes or within airports.

External battery packs are the leading cause of these incidents, prompting the FAA to ban them from checked baggage due to their increased difficulty in extinguishing. However, despite warnings and regulations, UL Standards and Engagement reports that approximately 40% of passengers still choose to check their battery packs.

Recent high-profile incidents, such as the Air Busan Airbus A321 at Gimhae International Airport in South Korea, which was destroyed by flames thought to have originated from a personal power bank stored in an overhead bin, highlight the potential catastrophic consequences of lithium battery malfunctions aboard aircraft.

In response, South Korea has implemented rules prohibiting power banks from being kept in overhead bins and barring in-flight charging devices. In the United States, Southwest Airlines now requires all battery packs to be kept in plain sight during use and forbids charging devices in overhead bins.

“We know that this is a solvable problem, and first and foremost, it is about passenger awareness and education,” said Jeff Marootian, the president and CEO of UL Standards and Engagement. “A lithium battery fire on the ground is dangerous enough, at 30,000 feet it can be a catastrophe.”

Passengers are encouraged to inform flight attendants if their devices exhibit unusual heat or if a battery-powered device is dropped into a seat. Additionally, choosing high-quality, well-manufactured devices can help minimize the risk of lithium battery malfunctions.