Thermal (2026)
Role Researcher
Tasks Interdisciplinary Research | Literature Review
Client Public Service | Personal Project


"I didn't think a battery that size would take my house down in 45 minutes."


Lithium-ion batteries (LIBs) and related battery technologies are increasingly essential, powering modern devices, vehicles, energy infrastructure, and more. However, such batteries can catch fire, reaching temperatures hotter than other types of fires. LIBs undergo a type of self-reinforcing reaction called thermal runaway leading to devastating damage and loss. LIB fires can be extremely difficult to extinguish and can reignite after they appear extinguished.

While LIB fires are relatively uncommon per device, the consequences can be severe. LIB fires can result in more than 3 times the property damage of an average fire from other causes. Incidents have occurred with phones and devices, power tools, drones, e-mobility, electric vehicles, aircraft, cargo shipping, battery factory*, energy storage facilities, and robots*, potentially leading to serious injury and death. More generally, any product or device containing one or more LIB may pose a fire risk. Recent incident tracking data shows that LIB fires are no longer rare events with 2500 incidents in 2025 from US fire data.

In response, lithium-ion batteries, of which there are various types, are being more strictly regulated or prohibited in commercial air travel and other domains. However, beyond the direct fire damage are hidden and less understood toxic contamination effects of lithium-ion battery fires. These toxic effects persist even after the initial flames are extinguished. Contamination can be odorless and invisible to the naked eye. The long-term implications for safety and material damage are not always well understood.

Thermal is a personal project to find resources on LIB fire impacts to human health, material/property damage, toxic contamination and the solutions. Please note, I'm not a certified professional in this field and LIB incidents should be reported to relevant authorities and emergency services. From my perspective as a health technology researcher, the dangers of inadequate knowledge and the widespread use of potentially faulty LIB products cannot be underestimated especially in the context of aging-in-place where individuals already require additional help in technology use. LIBs pose disproportionate risks to elderly safety due to the violent and rapid nature of the fire, release of toxic gases, and long-term contamination.

Selected public domain resources and article links from the scientific literature, industry sites and reports, and regulatory sources are provided in the Articles List for easy reference. These were selected for their relevance to LIB fires, with a focus on health effects and fire contamination toxicity. Of course, this brief survey is only scratching the surface. Ultimately, the goal is to improve awareness and understanding to motivate better safety, prevention, mitigation and restoration practices.

I outline solutions and practical know-how for LIB safety and post-fire incident response. Technical videos on fire simulation, chemistry, and recent LIB safety research are included at the end. Lastly, currently reported LIB incidents can be tracked at the Battery Fire Watch dashboard.

* There are lithium metal batteries which are typically non-rechargeable and have different chemistry than lithium-ion but can be just as deadly.

* Humanoid Robots Safety Considerations from Design to Deployment (video mentions LIB risks in this emerging category).

"Safety is not a gadget but a state of mind."
Eleanor Everet

"Facts do not cease to exist because they are ignored."
Aldous Huxley

"When It Comes To Safety, There Are No Shortcuts."

Articles List



AIHA (American Industrial Hygiene Association) interview with a certified industrial hygienist, safety professional and AIHA Fellow. Some statements relevant to LIB fires from the video:

"A lot of people think wow my home survived this wild firestorm, the urban wildfire that ate up my neighborhood but somehow by some grace my house survived and they're so excited to get back in their house but it's actually what they think is a blessing actually ends up to be somewhat of a curse. An unexpected curse because of the particulate that has blown through their home and infiltrated their home, every nook and cranny and kind of remains in their home until it's cleaned properly..."



This video shows real-time, instrument detection of the emission of high levels of toxic gases from burning lithium-ion battery. These hazardous gases include hydrogen fluoride, hydrogen cyanide, carbon monoxide, carbonates, formaldehyde, benzene, etc. Here is a short video about formaldehyde and fire.

toxic emissions chart

LIB fires can create a large variety of toxic emissions beyond what was shown in the above video. Hazards associated with some substances that could be released by damaged batteries as identified by Nedjalkov et al.
Source:
Toxic Gas Emissions from Damaged Lithium Ion Batteries—Analysis and Safety Enhancement Solution,

toxic emissions chart 2

This is another version of the table above showing substance hazards. The well known polychlorinated biphenyls (PCBs) are derived from biphenyl. There are also toxic metal nano-oxides.

HCl

Hydrogen chloride (HCl) can also be emitted from LIB fires [4]. HCl is a well-known gas from volcanic eruptions and is a colourless gas with an irritating pungent odor [5]. According to Hull [6], HCl presents two significant hazards in fires, by causing incapacitation through sensory irritancy (leading to painful breathing, swelling of the airways, and ultimately death), and by inhibiting the conversion of CO (Carbon Monoxide) to CO2 (Carbon Dioxide).

What are PAHs?

LIB fires can also emit cancer-causing polycyclic aromatic hydrocarbons (PAHs). PAHs can persist for years. Another risk from fire emissions is chemical respiratory sensitization and asthma [8,9].

Sources:
1. Environmental Impact of Lithium-Ion Battery Incidents Compared to Other Common Incidents
2. Spatiotemporal analysis and human exposure assessment on polycyclic aromatic hydrocarbons in indoor air, settled house dust, and diet: A review
3. Environmental impacts, pollution sources and pathways of spent lithium-ion batteries.
4. Review of gas emissions from lithium-ion battery thermal runaway failure — Considering toxic and flammable compounds
5. Hydrogen Chloride (HCl) - from International Volcanic Health Hazard Network (IVHHN)
6. Hydrogen Chloride in Fires
7. You've Heard of PFAS, but What are PAHs?
8. “Air That Once Was Breath” Part 1: Wildfire-Smoke-Induced Mechanisms of Airway Inflammation
9. Chemical respiratory sensitization—Current status of mechanistic understanding, knowledge gaps and possible identification methods of sensitizers

environmental spread

LIB fires can spread toxic metals, carbonaceous particles, and electrolyte residues into the surrounding environment. Lithium-ion batteries risks also include PFAS ("forever chemical") pollution. It it said that "wildfires don't just destroy homes—they poison those that survive". One can argue that the same can be said for LIB fires.
Source:
A Review of Fire and Explosion Hazards in Sustainable Lithium-Ion Battery Recycling Industries

Statements from surveyed articles and media on LIB fire risks


"...You cannot treat a battery fire like a toaster fire. The residues do not just smell bad. They are chemically active and they do not stop when you turn on a fan. If you had visible smoke, you had invisible chemistry riding along with it. [1] "

"Commercial lithium-ion batteries can emit considerable amounts of HF [Hydrogen Fluoride] during a fire and that the emission rates vary for different types of batteries." "The immediate dangerous to life or health (IDLH) level for HF is 0.025 g/m3 (30 ppm) and the lethal 10 minutes HF toxicity value (AEGL-3) is 0.0139 g/m3 (170 ppm)." "The release of hydrogen fluoride from a Li-ion battery fire can therefore be a severe risk and an even greater risk in confined or semi-confined spaces." [2]

"Drivers, stevedores, ships' crews and first responders attempting to control the blazes encounter what might appear to be smoke but is in fact a mix of toxic gases, generated quickly and in large volumes. These gases once in the atmosphere behave differently to smoke, often pooling at floor level due to their density. "Traditionally where fires and smoke are concerned one would stay low to avoid inhalation, doing so where lithium battery fires are concerned is likely to prove problematic," observes Dalus." [3]

"One of the most frustrating parts of lithium-ion battery fire cleanup is that what you see is not what you get. Even rooms that did not burn can corrode. There is a documented case from Newfoundland where a tool battery fire threw off soot and acidic byproducts that later corroded an electrical panel and metal surfaces that never saw open flame." [1]

"Beyond electrical components, the potential long-term effects of lithium battery fire residue on other household materials were largely overlooked. HF exposure can gradually deteriorate plastics, rubber seals, and insulation materials. Soft goods like clothing and furniture can also become contaminated and may be difficult to fully restore." [4]

"There are a number of possible causes for battery failures and at least a part of the field failures are often considered as spontaneous internal cell short circuits. They start at a micrometer scale inside a cell with a short circuit rapidly increasing the local temperature. It is extremely difficult, if not impossible, to detect these types of failures before they happen." [5]

"Inside every rechargeable electronic device lives a small chance of danger, a risk that becomes compounded by the sheer quantity of gadgets around us and number of battery cells inside each one. Battery fires and explosions are extremely dangerous and have resulted in millions of dollars in damage, injuries, and deaths. Data from Erie Insurance reveals that lithium-ion battery fires are not only occurring more often than they have in the past, but they also result in more than 3 times the property damage of an average fire from other causes." [6]

[All Emphasis Mine]

[1] HF Acid Risks in Li-Ion Fire Cleanup

[2] Toxicology of the Lithium Ion Battery Fire

[3] Fire not the only danger with lithium ion batteries

[4] What the recycling industry can learn from residential lithium ion battery fires

[5] Larsson, F. (2017). Lithium-ion battery safety-assessment by abuse testing, fluoride gas emissions and fire propagation. Chalmers Tekniska Hogskola (Sweden).

[6] Lumafield Battery Quality Report

Solutions Watch

1. Prevent LIB fires in the first place by looking up your LIB containing item for recalls and safety warnings. Discard defective lithium-ion batteries appropriately using recycling centers or hazardous & e-waste collection services. Do not put devices in the trash! Spent LIBs are hazardous wastes. There are emerging technologies using computed tomography (e.g. lumafield.com) and acoustics for detecting defects in the battery. It is said that lithium iron phosphate (LFP) type of lithium-ion battery is safer but research is showing how caution is warranted for all types of batteries.

United States Consumer Product Safety Commission (CPSC)

Find recalls, advisories and safety alerts (Canada)

Underwriters Laboratories Public Notices

Lumafield Battery Quality Report

Lithium-Ion Battery Condition Monitoring: A Frontier in Acoustic Sensing Technology

How safe are lithium iron phosphate batteries?

Environmental impacts, pollution sources and pathways of spent lithium-ion batteries


2. Make sure batteries and battery chargers (like USB chargers) are properly certified such as with UL (USA) or cUL (Canada), ETL, IEC, national certifications etc. For battery energy storage systems (BESS), CE certification is stated to be necessary but not enough to prove safety compliance.

UL Certification Information Search

ETL Listed Mark | Product Certification

TÜV SÜD

TÜV SÜD - 8 Ways To Avoid Fire and Explosion in Lithium-Ion Batteries

CCC certification

“CCC” Certification for Li-ion Batteries Around the Corner

CE Marking vs. UL 9540: Understanding Global Safety and Compliance for BESS

CE for BESS: Complete Guide to Battery Energy Storage Certification


3. Safer ways to charge batteries inside protective containers, outside, and on nonflammable surface. Also, safer ways to store them such as not leaving LIB batteries in storage or shipping them at 100% state of charge. How to effectively put out a LIB fire is an active research area. Some have advocated for the use of specialized suppression blankets and mineral based materials. Normal home fire extinguishers (Class ABC) can work on small lithium-ion battery fires (small devices) but not larger fires (like from e-bikes, vehicles, energy storage). There is always the risk of reignition with LIBs. Charge and store batteries in a cool, dry place. Never leave batteries in hot vehicles or under direct sunlight.

How good are BAT-SAFE and METAL BOXES? LiPo fire true & detailed test (pt. 2/3)

5 Best Fireproof Lithium Battery Container | Don’t Trust a Pouch

Can Lithium-ion Battery Fires be Extinguished: Small/Medium Devices

How to Put Out a Lithium Ion Battery Fire: Safety Guide for 2026

CellBlock Solutions & Mineral-Based Media for Extinguishing Li-ion Battery Fires

Lithium Battery Safety

StacheD Training - Lithium-ion Battery Fires: Full Charge vs. Low Charge


4. Exposure to toxic hydrogen fluoride (HF) and hydrogen cyanide (HCN) require specialized interventions such as calcium gluconate for HF exposure on skin. It is critical to avoid prolonged exposure to the contaminated site of the fire.

Medical Management Guidelines for Hydrogen Fluoride

What Is Cyanide Poisoning?

What to Do if You Inhale Lithium Battery Fumes?


5. Research is showing how to clean or reduce the concentration of toxic PAHs emitted from LIB fire using ethanol, commerical glass cleaner, or citrus based cleaning agent. Simple cleaning techniques like damp dusting may also be helpful. However, depending on the extend and severity of contamination, many items like clothing, electronics, furniture, will harbor toxic contamination that cannot be removed easily or without damaging the item. These items will need to be completely discarded and replaced. It is recommended to contact professional restoration and hazmat services.

Targeted household cleaning can reduce toxic chemicals post-wildfire

Polycyclic Aromatic Hydrocarbons (PAHs) In Wildfire Smoke Accumulate On Indoor Materials and Create Post-Smoke Event Exposure Pathways

5 on the Frontline with Dawn Bolstad-Johnson

Acute Treatment with Kerosene Damages the Dermal Barrier and Alters the Distribution of Topically Applied Benzo(a)pyrene in Mice

Polycyclic Aromatic Hydrocarbons Fact Sheet

Damp Dusting

NLR Restoration - Lithium-Ion Battery Fire Damage Cleanup

Mayfield Environmental Solutions - Battery Fire Cleanup & Decontamination

Polygon - Lithium-Ion Battery Fire Restoration
(Note the use of Polygon FW 102 alkaline soap for decontamination)
(https://www.polygongroup.com/en-GB/services/major-complex-claims/lithium-ion-battery-fire-restoration/)



6. In many cases, complete removal and replacement of contaminated items is required. Other interventions are removing HVAC ducting, cleaning AHU (air handling unit), removing attic insulation, removing all drywall and porous materials like wood.

How lithium-ion fires create hidden risks for recyclers

What the recycling industry can learn from residential lithium-ion battery fires + hidden corrosion in homes

What To Throw Away After Smoke Damage Guide


7. Biochar can contribute to LIB fire contamination clean up through adsorbing (collecting on the surface) heavy metals and other contaminants. There is emerging research on how bacteria in fog helps clean the air of toxic formaldehyde. Researchers are investigating whether microbes can help break down fluorinated contaminants like PFAS.

Biochar's Role in Cleaning Up Lithium-Ion Battery Fire Sites

Growth and formaldehyde degradation of photoheterotrophic Methylobacterium within radiation fogs

Can microbes save us from PFAS?


8. Photocatalytic oxidation can be useful to remove certains VOCs and odors but not as a complete decontamination solution.

Photocatalytic Oxidation for Volatile Organic Compounds Elimination: From Fundamental Research to Practical Applications


9. Liquid carbon dioxide (CO2) cleaning for clothing decontamination after exposure to LIB fire. Texas A&M Engineering Extension Service report states liquid "CO2-based cleaning was highly effective, with many SVOCs being undetected in the cleaned gear", more effective than water based methods.

LITHIUM-ION BATTERY FIRES AND EMISSIONS CHARACTERIZATION REPORT


10. Structural pasteurization or heating can help reduce odors and VOCs.

Structural Pasteurization


11. Better simulation of spread of contamination can lead to more effective clean-up and restoration efforts. The link below is to software for artistic and creative purposes. However, one can propose a purpose-built fire dynamics simulator to guide post-fire decontamination effort such knowing what areas of a home to replace or focus cleaning efforts. For instance the simulator can show how different contamination particles settle in different places post-fire according to a phenomenon called "thermophoresis". National Institute of Standards and Technology (NIST) is developing a "Fire Dynamics Simulator" and scientific simulation software that can model fire dynamics, including deposition of smoke and aerosols onto solid surfaces.

Escape Motions fire smoke, dust, airflow and structural barriers simulation example

Thermophoresis (Wikipedia)

NIST Fire Dynamics Simulator (FDS) and Smokeview (SMV)

NIST Simulation of the Dynamics of a Fire in a Two-Story Duplex

Firetools - A collection of open-source tools for fire safety engineers, firefighters, researchers,and students.


12. An industrial hygienist (IH) or forensic industrial hygienist can and should investigate the site of the fire for damage and contamination using a variety of detection, sampling, and analytical techniques. Findings are used to guide and scope decontamination and restoration efforts, insurance claims, etc.

What Is an Industrial Hygienist (IH)?

Detecting VOCs and SVOCs: A Guide to Sensor Technologies - Smart Detect


13. Where to find post-fire cleanup services? Also see restoration services links from #5.

Best Fire Damage Restoration Services (Forbes.com)


14. Specialized training for first responders to portable electronics fires. StacheD Training "identify risks within your facility, help you reduce them, and train your employees to respond effectively to fires and thermal runaway events—keeping your team safe."

StacheD Training - Consulting | Risk Reduction | Training

Portable Electronic Device (PED) Fire Training – Cabin


15. Further reading and books on LIB risks and safety plus general fire incident recovery tips.

Lithium Ion Battery: Safety in Focus - Prevention and Mitigation of Risks by Meira, Felipe

The Safety Challenges and Strategies of Using Lithium-Ion Batteries

Battery Design | Safety (Technical explanations of basic LIB concepts, resource for engineer)

Safety by Design: A Next-gen Blueprint for EV Batteries
"The EV industry can – and should – stop pushing decades-old battery architecture well past its limits."


Battery Chemistry Research: Safer, Sustainable Alternatives to Lithium-Ion Batteries for Energy Storage

The Red Guide to Recovery "is a comprehensive, easy-to-read, handbook to help walk survivors step-by-step through the disaster recovery process".

Practical guidance for post wildfire cleanup (National Collaborating Centre for Environmental Health | NCCEH - CCSNE)

Cleaning Up After a Fire (American Red Cross)

CalEPA Residential Environmental Hazards: A Guide For Homeowners, Homebuyers, Landlords and Tenants, 2011

A push to end a fractured approach to post-fire contamination removal (Los Angeles Times)

Decontamination Basics

"Contaminants can be located either on the surface of personal protective equipment or permeated into the PPE material. Surface contaminants may be easy to detect and remove; however, contaminants that have permeated a material are difficult or impossible to detect and remove. If contaminants that have permeated a material are not removed by decontamination, they may continue to permeate to either surface of the material where they can cause an unexpected exposure.

Five major factors affect the extent of permeation:

Contact time. The longer a contaminant is in contact with an object, the greater the probability and extent of permeation. For this reason, minimizing contact time is one of the most important objectives of a decontamination program.

Concentration. Molecules flow from areas of high concentration to areas of low concentration. As concentrations of wastes increase, the potential for permeation of personal protective clothing increases.

Temperature. An increase in temperature generally increases the permeation rate of contaminants.

Size of contaminant molecules and pore space. Permeation increases as the contaminant molecule becomes smaller, and as the pore space of the material to be permeated increases.

Physical state of wastes. As a rule, gases, vapors, and low-viscosity liquids tend to permeate more readily than high-viscosity liquids or solids."

Source: https://www.osha.gov/hazardous-waste/decontamination




"The time between exposure of the skin and decontamination is critical. Ideally, decontamination should be done within the first two minutes, before the agent penetrates the skin, because topical decontaminants are not effective for chemical agents that have penetrated the skin (Hurst, 1997). However, decontamination after 15 minutes of exposure can still be of value although it may not be as effective.

Washing with soap and water has always been assumed to remove chemical and biological materials from the skin. However, recent evidence suggests that penetration and systemic absorption/toxicity may actually be increased by washing (Wester and Maibach, 1999b, 1999c). Washing is also ineffective for decontaminating painted surfaces."

Source: https://www.ncbi.nlm.nih.gov/books/NBK225134/

Fire Simulation



Escape Motions simulation of smoke rising and spreading onto surfaces and crevices in an enclosed space. Air emitter on the left side simulates an open window with wind blowing into the space. Top (ceiling) gaps can approximate features like recessed lights with gaps allowing smoke to enter into the interstitial space. More specialized and accurate simulations can be obtained with purpose-built tools like NIST Fire Dynamics Simulator (FDS) as shown in the video below.





NIST Fire Dynamics Simulator (FDS) and visualization of a multi-story, single-family dwelling electrical fire (see NIST Technical Note). Simulation shows how a stairway in the home became a chimney for hot gases that allowed these gases to spread and how changing fire "flow paths" are a danger to firefighters and occupants.

NIST Technical Note - Simulation of a Fire in a Hillside Residential Structure - San Francisco, CA

PAH Forensics



Technical presentation for those inclined. Pattern recognition, laboratory bias, and the wild wild west of forensic chemistry. "Don't write off any outlier."

Progress on fire research of Lithium-ion battery (2021, 2026)






One certainly would want to prevent LIB fires in data centers.

Quotes:

"Any purposeful action will produce some unanticipated or unintended consequences."

Law of Unintended Consequences

"Second order effect refers to the idea that every action has a consequence, and each consequence has a subsequent consequence."

Source: Second-Order Effect in Product Design and Strategy

"The system always kicks back. — Systems get in the way — or, in slightly more elegant language: Systems tend to oppose their own proper functions. Systems tend to malfunction conspicuously just after their greatest triumph."

"A complex system that works is invariably found to have evolved from a simple system that worked. The inverse proposition also appears to be true: A complex system designed from scratch never works and cannot be made to work. You have to start over, beginning with a working simple system."

Both quotes above from John Gall