In recent months, a spate of electric vehicle (EV) battery explosions has raised serious safety concerns in Australia.
As the country gears up for an electric future, these incidents illuminate the potential hazards associated with lithium-ion batteries and pose critical questions about EVs’ long-term viability and safety.
Electric vehicles, celebrated for their role in reducing carbon emissions and paving the way towards a greener future, have recently come under the spotlight due to their reliance on lithium-ion batteries. These high-energy-density batteries, while efficient, are prone to thermal runaway conditions that can lead to fires and explosions. Thermal runaway can occur due to manufacturing defects, external damage, or improper charging practices emerging as a critical challenge that could undermine consumer confidence.
Dr Raghavan Prakash, an expert in EV engineering at the University of Western Sydney, has contributed to various projects aimed at EV technology, particularly in battery technology, powertrain development, and vehicle design, collaborating with industry leaders and research institutes.
“The challenge is when these electric vehicles do light on fire, they can create quite an unsafe area because these battery fires can even create an explosion risk and emit very toxic gasses and chemicals,” Dr Prakash said.
“Lithium-ion battery fires start with thermal runaway. This self-sustaining chemical reaction within the battery can spark a fire. This happens if there is damage to the battery, and the ensuing chemical reaction causes a cell to become overheated. It can’t cool down, causing a chain reaction that heats neighbouring cells,” he said.
According to the EV battery fire incidents analysed by EV Firesafe, the leading causes globally of thermal runaway leading to EV battery fires are collisions and road debris impact (22.5% as of April 2024), defects in manufacturing (9.7%), submersion in water (5.6%), and arson or external fires (6.9%).
In a recent incident, sparks from a detached lithium-ion battery from a luxury car at Sydney Airport spread to five nearby vehicles, causing a significant fire. Another fire at Penrose in the NSW southern highlands involved an EV catching fire after hitting debris on the road. Firefighters also responded to blazes set off by an electric vehicle charging station in Berkeley, a garden hedger in Lake Macquarie, and a loose battery in a garbage truck passing through Silverwater. Although experts maintain that EV fires are rare, these high-profile incidents have ignited public fear and scepticism.
The frequent reports of battery explosions have shaken consumer confidence in electric vehicles. Despite assurances from experts and regulators, the fear of potential fires poses a significant barrier to the widespread adoption of EVs in Australia. A recent survey by the Australian Automobile Association found that nearly 40% of respondents expressed concerns about battery safety when considering an electric vehicle. This anxiety is exacerbated by media coverage that often sensationalises incidents, leading to heightened public perception that EVs are inherently dangerous.
While EV manufacturers are generally well-regulated, there is a growing need for tighter controls on smaller battery-operated devices including e-scooters and e-bikes, which have been linked to a higher frequency of battery fires. Dr Prakash emphasises the importance of regulatory oversight.
“A lot of those devices have substandard lithium-ion manufacturing processes or battery management systems which are inherently unsafe compared to other premium products,” he said.
To reduce fire and other safety risks, all vehicles sold in Australia must adhere to strict ADR regulations, which include rules for cars with electric powertrains (Australian Design Rule 109/00). ADR 109/00 reflects Australia’s commitment to promoting the safe integration of electric vehicles into the automotive landscape while supporting the transition to cleaner energy sources. The ADR regulations do not apply to other devices powered by lithium-ion batteries.
The Fire and Rescue NSW (FRNSW) and the Environment Protection Authority have launched an awareness campaign to inform the public about the risks associated with lithium-ion batteries and the need for their safe disposal. FRNSW will reinforce its public messages to households and businesses to use extra caution with Lithium-Ion batteries and other related devices.
Fire and Rescue NSW has tackled 63 fires from lithium-ion batteries in 2024, at an average of nearly six a week. Fire and Rescue NSW is leading a collaborative research program on the Safety of Alternative and Renewable Energy Technologies (SARET).
Inspector Paul Smith of Fire and Rescue NSW has addressed the challenges posed by electric vehicles and the intent behind the SARET research program for specialised training and response strategies.
“The purpose of this project is to understand the risks related to fire propagation within and between stationary Battery Energy Storage Systems (BESS) due to external factors to aid in the prevention of injuries to people and minimisation of damage to buildings, infrastructure and the environment,” Inspector Smith said.
While EV battery fires are rare, first responders are at the forefront of risks when dealing with EV battery fires. Unlike conventional internal combustion engine fires, EV battery fires present unique hazards that require specialised training and equipment. The complex nature of lithium-ion batteries means they can reignite hours or even days after the initial incident, creating prolonged risks for responders and the public.
“In addition to the immediate dangers posed by the fires, there is also the challenge of safely extricating victims from crashed EVs. Although EV fires in crash incidents are less likely, the high voltage systems within these vehicles can remain live even after a crash, posing electrocution risks to both the occupants and rescuers. Without proper training, first responders might inadvertently worsen the situation.”
The SARET research program will partner with other fire services and research institutions. It will address the best-practice fire brigade response to lithium-ion battery-related fires, end-of-life lithium-ion battery hazard management, electric vehicle fires in structures, and fire propagation in battery energy storage systems.
Inspector Smith shares insight on the importance of fire protection materials in batteries as well as preventative measures in EVs to enhance safety during incidents, “Fire protection materials including ceramics, mica sheets, encapsulating foams and aerogels, should be integrated into battery designs to help control fires and prevent them from spreading. These materials can significantly enhance the overall safety profile of EV batteries. Other preventative measures in electric vehicles include using a cooling shroud filled with coolant liquid to prevent external damage or short circuits.
Inspector Paul Smith urges EV owners to use blue EV stickers on their vehicles to help ensure that appropriate steps can be taken to prevent potential hazards in the event of an accident. Inspector Smith also advises all EV owners to install smoke or heat alarms in garages and that all charging connections should be installed by a qualified electrician.
Dr Prakash is currently developing a safety course around the use of batteries, aiming to educate EV owners about potential hazards and how to manage them. He stresses the importance of preventive measures.
“It’s important EV owners read their vehicle manual, and most models have a mobile app that detects any potential issues with the battery system,” he said.
The course covers various critical areas, including understanding EV technology, identifying and mitigating risks associated with battery fires, and safe extrication techniques. It also emphasises the importance of understanding different emergency services to ensure a comprehensive and effective response.
Dr Prakash highlighted the crucial need for greater awareness and education regarding the risks associated with lithium-ion batteries.
“Insights into lithium-related fires will assist consumers in continually developing the best practices for an emergency response to a fire and also understanding the measures to manage the risks associated with emerging technologies.”
Advanced battery management systems (BMS) are also being developed to adequately monitor and control the temperature and charge levels of the individual cells, thereby reducing the likelihood of thermal runaway. Additionally, the integration of new battery chemistries, such as solid-state batteries, promises higher safety margins and improved performance.
Australia’s EV market is at a critical juncture. As of July 2023, there were 130,000 EVs on Australian roads, with 57,000 purchased in the first seven months of the year alone. This rapid growth underscores the importance of addressing safety concerns to sustain consumer confidence and ensure the long-term viability of electric vehicles.
The future of electric vehicles in Australia appears promising, driven by technological advancements, regulatory support, and changing consumer attitudes. As automakers continue to innovate, the landscape of EV technology is evolving rapidly. By 2030, it is anticipated that battery prices will continue to decline, making EVs more accessible to a broader range of consumers, also driven by initiatives such as tax incentives, rebates and investments in charging infrastructure.
While the current data from the Australian-based research company EV Fire Safe prominently indicates that EV battery fires are rare, the potential risks cannot be ignored. The incidents at Sydney Airport, Penrose and Berkely serve as reminders of the importance of rigorous safety measures and regulatory oversight in the rapidly evolving EV landscape.
The recent spate of battery explosions in electric vehicles highlights a critical challenge for the EV industry in Australia. Ensuring the safety of lithium-ion batteries is paramount to maintaining consumer trust and fostering the widespread adoption of EVs. As manufacturers, researchers, and regulators work together to develop safer battery technologies and implement stringent safety standards, the future of electric vehicles in Australia looks promising, nonetheless with cautious optimism. Addressing the challenges posed by flammable batteries, the industry can pave the way for a safer and greener future for electric vehicles in Australia.
Rajneel Rahil Lal
UOWTV