A fire in a lithium-ion battery pack is not an ordinary fire. The behavior is more explosive, the smoke more toxic, and the risks for emergency responders are significantly higher. That’s precisely why it’s crucial to be able to train for this type of incident properly. And that requires a different approach to simulation.
At FireWare, we develop scenarios and tools that allow you to recreate these kinds of situations as realistically as possible. We simulate thermal runaways with flames and the sound of exploding battery cells. In this blog, we dive into the how and why of lithium-ion (Li-ion) simulations.
What makes a Li-ion fire so different?
Lithium-ion batteries have become an integral part of our daily lives. We find them in bikes, scooters, cars, laptops, power tools, and storage systems. But when something goes wrong, it becomes serious very quickly. A fire in a Li-ion battery pack behaves differently from a regular fire – and therefore requires a different response approach from emergency services.
An important phenomenon in this context is the so-called thermal runaway: an uncontrollable chain reaction within a battery pack.
How does a thermal runaway occur?
A thermal runaway (TR) usually occurs when a battery cell becomes internally damaged. This can happen if the battery pack takes a hit, for example in a collision. The damage causes an internal short circuit, which rapidly heats up the cell. That heat spreads to adjacent cells, which then also fail. This creates a chain reaction where cells explode one after another, releasing highly toxic gases. The challenge is that this process is nearly impossible to stop.
Cause and effect: the dynamics of Li-ion incidents
In a thermal runaway, the battery pack is often just the beginning. The heat released almost always causes the surrounding area to catch fire as well. Take an electric car, for example. If the fire starts in the battery pack (such as after a collision), the rest of the vehicle will eventually also catch fire.
Of course, it’s also possible for a fire to break out in an electric vehicle without the battery pack (yet) being involved. It’s important to recognize the difference between a vehicle fire with and without battery involvement. This distinction has a direct impact on the risks and the response strategy.
Another example:
A fire breaks out in a warehouse shelving unit. Nearby, there’s a pallet with bicycle batteries. Once one of the batteries overheats and goes into thermal runaway, the process in that specific battery is almost impossible to stop. However, depending on how the batteries are packaged, it may still be possible to prevent others from being affected.
For training purposes, this means you need to consciously choose which cause you want to simulate – and which effect. So don’t just stage a battery fire or an object fire, but show how they interact – or deliberately don’t.
Double staging: battery fire and surrounding fire
Precisely because of this dynamic, double staging is often the most realistic. We distinguish three variants:
- The battery fire, with pulsating flames, explosions, and (toxic) smoke
- The consequential fire, where the battery fire spreads to the surroundings
- The cause fire, where an external fire heats the battery pack so much that a thermal runaway still occurs
Each of these variants requires a different approach, different resources, and a different learning objective. Therefore, it is important to consciously design your staging.
Staging tools
Simulating battery fires
Use the FireSpot MK2 or FireSpot XXL with built-in programs. One of the patterns is specifically designed for thermal runaway and displays a pulsating light effect. Aim this spot from the back into a smoke layer to simulate the effect of exploding battery cells.
Combine this with a powerful smoke machine, such as the FireWare Stratus, for sufficient smoke output. Optionally, make the smoke pulse for extra effect.
The Pandora’s Box 230 completes the scenario. You control your staging from your smartphone and add the characteristic sound of exploding cells.
Simulation set Large (including Thermal Runaway)
The products mentioned above, along with the Phoenix and the FireWare Sample Kit Smoke Fluid, are also available in a training kit: the Simulation Set Large.
A complete value pack for creating large, dynamic training scenarios.
To summarize, the set includes:
- Pandora’s Box 230
- Stratus smoke machine
- Phoenix Silkflame
- Firespot MK2
- Firespot XXL
- Sample Kit Smoke Fluid
Simulation Set Medium (includes Thermal Runaway)
The Simulation Set Medium: an all-in-one value pack to create medium-sized dynamic scenarios.
This set contains:
- Pandora’s Box 230
- Cumulus Smoke Machine
- Phoenix Silkflame
- Firespot MK2
- Mini-Silkflame LED
- Sample Kit Smoke Fluid
Simulation set Small (including Thermal Runaway)
The Simulation Set Small: an all-in-one value pack to create small dynamic scenarios.
This set contains:
- Pandora’s Box 230
- FireSpot MK2
- Mini Silkflame
- Nimbo Smoke Machine
- Sample Kit Smoke Fluid
Simulating Environmental Fires
Use a steadier light pattern for this. The FireSpot MK2 and FireSpot XXL are also suitable here, provided they are set to a different program. Alternatives include the FireSpot Original, Mini Silkflame or Phoenix Silkflame.
You can also easily connect these devices to the Pandora’s Box 230 for centralized control.
And what if water is involved?
‘Cool, cool, cool’ is often the motto. In a training situation, we usually don’t use water, but if this is an important part of your learning and training goals, you need to ensure your staging materials can withstand it.
The FireSpot MK2 and FireSpot XXL are waterproof, including connectors – so you can safely use them with real extinguishing.
Smoke machines require a bit more attention. Place them at a distance from the wet operation area and use a smoke hose; either perforated or sealed. Note: pulsing smoke through a hose is tricky. Use light and sound for the ‘exploding’ effect.
Learn everything about staging battery fires! Watch along!
This month, we’re sharing a series of ‘How-to’ videos on our socials. From bicycle batteries to electric cars – everything is covered. We show you how to build, combine, and tailor scenarios to your learning objectives: follow us on social media (scroll down to the bottom of this page for our social accounts)!
Want to set up your own battery fire scenario?
We’re happy to help you design a setup that fits your goals, target group, and equipment. Call, email, or visit us!
