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Process Safety Implications of Lithium-Ion Battery Development

Lithium-Ion Battery Development

With the growing demand for electric vehicles and energy storage, our client, a global leader in sustainable technologies, expanded their research and development (R&D) into lithium-ion battery technology.

Project Summary

Sector

Capabilities

Service

The before:

The project involved testing new battery compositions and optimising manufacturing processes for large-scale production. However, lithium-ion batteries present several safety challenges due to the use of flammable electrolytes and the potential generation of explosive gases during battery failure or stress testing. The client recognised the need to manage these risks, particularly under the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR), which govern potentially explosive atmospheres in the workplace.

The during:

A comprehensive DSEAR risk assessment was conducted to ensure workers and the facility’s safety. This risk assessment identified several hazards: the potential release of flammable gases during overcharging or thermal runaway scenarios, the risk of dust explosions from metal powders, and the danger of electrostatic discharge (ESD) igniting these substances. To mitigate these risks, we recommended that our client implement multiple safety layers, including redesigned test chambers, gas detection systems, and improved ventilation. The battery testing protocols were adjusted to include remote monitoring, minimising employee exposure to high-risk areas during critical testing.

The result:

Following the risk assessment and implementation of control measures, the client significantly reduced the potential for explosive atmospheres in their testing and manufacturing environments. An Explosion Protection Document (EPD) was developed, outlining the control measures and safety protocols in place to manage the risks. By proactively addressing the DSEAR requirements, the client not only improved safety but also ensured regulatory compliance, reducing liability and strengthening their position as an industry leader in battery technology. Moreover, the team’s enhanced understanding of DSEAR and potentially explosive atmospheres in their process ensured their designs for production were safe and compliant with DSEAR.

This case highlights the importance of integrating DSEAR and process safety management into the development and manufacturing of lithium-ion batteries, ensuring both innovation and safety in potentially hazardous environments.

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