Recharging Responsibility: The Fire Risk Behind Rising Battery Recycling in the U.S.

The rise in lithium-ion battery fires and explosions are becoming a major concern. Battery-related fire incidents have risen sharply with the increasing use of these batteries in consumer electronics and electric vehicles (EVs). In the U.S., a new tracking tool identified 50 lithium-ion battery fires at various waste and recycling facilities within a six-month period in 2023 (Massachusetts Department of Fire Services 2024). These fires typically occur when batteries are discarded improperly, mixed with other waste, or damaged during the recycling process.

The U.S. is facing a surge of end-of-life (EOL) batteries as EVs and rechargeable devices become more popular. By 2030, the country is projected to have to handle 11 million metric tons of spent lithium-ion batteries, creating significant challenges for recycling and safe disposal (Leal et al. 2023). This influx is expected to overwhelm an already underprepared waste handling infrastructure, further increasing the risk of fires if not managed correctly.

The Growing Challenge: Billions of Batteries

The scale of the battery waste stream is staggering. In the United States alone, it is estimated that over 3 billion batteries are discarded annually, with most being improperly discarded at the end of their life (CDDl Recycling 2022). This problem is amplified by the growing number of electric vehicles and other high-capacity battery-powered devices. Unfortunately, many waste management facilities are not equipped to handle the growing volume of batteries being discarded, leading to improper disposal and increasing the risk of fires (Ginger Krentz 2024).

Growing battery waste highlights the urgent need for improved recycling and disposal solutions.

The Hidden Costs of Battery Fires

Fires caused by lithium-ion batteries discarded in waste or incorrect recycling streams are becoming more frequent. A report by the US Environmental Protection Agency found 64 waste facilities experienced 245 fires that were caused by, or likely caused by, lithium metal or lithium-ion batteries (Office of Resource Conservation and Recovery 2021). These fires are often catastrophic, requiring extensive resources to extinguish and causing costly damage to infrastructure. Insurance rates have increased from less than 20 cents per $100 of insured property value to as much as $10 per $100 as providers recognize the growing threat of catastrophic fires to material recovery facilities, according to members of the insurance industry (Shelley Mann 2024). Consequently, fire departments and waste facilities are now calling for stricter disposal guidelines and better fire prevention strategies.

Neutralizing Batteries for Safety

Neutralizing waste batteries is crucial in preventing fires, especially in factories and recycling centers where these batteries can short-circuit, overheat, and ignite adjacent materials. As part of efforts to reduce fire hazards, companies are investing in battery neutralization technology, which removes flammable and toxic electrolytes and “forever chemicals” from dead batteries before they are sent for further processing.

In 2023, the Department of Energy allocated $62 million to fund 17 battery recycling projects, many of which focus on neutralizing lithium-ion batteries to eliminate fire and environmental risks they pose (Ray Chalmers 2024). By making batteries inert, the risk of fires during transportation and recycling is eliminated. This step is a bare minimum for safely managing battery waste, especially as the volume of discarded batteries continues to grow. An ideal neutralization system would de-energize and safely extract and recycle the electrolyte which includes carbonates and lithium salts. This completely removes fire and explosion risk.

Neutralizing batteries before recycling is key to preventing fires and ensuring safe disposal.

Harnessing Technology to Tackle Battery Waste

Waste management facilities are developing new protocols for safely collecting, transporting, and neutralizing used batteries (Battery Recyclers of America 2023). These protocols include isolating batteries from general waste, using fireproof containers for storage, and ensuring that all batteries are discharged or neutralized before disposal. The US Environmental Protection Agency (EPA) has also published detailed guidelines for the safe disposal and recycling of lithium-ion batteries (US EPA 2019). These guidelines emphasize the importance of neutralizing batteries before they are transported to recycling facilities to minimize fire risks.

Preventing Battery Fires: The Urgent Need for Safer Recycling Solutions

The escalation in insurance costs due to growing prevalence of lithium-ion battery fires highlights the urgency for systematic changes in how the United States manages battery waste. Mitigating the fire risk posed by discarded batteries is the crucial first step of the recycling process. The scale of the problem is vast, and without robust safety protocols, neutralization technologies, and improved disposal methods, the risks to waste management facilities, recycling centers, and surrounding communities will only increase. With millions of tons of batteries expected to reach the end of their life in the coming years, it’s crucial that both industry and regulatory bodies continue to invest in and develop strategies that prioritize fire prevention, ensuring a safe, profitable and sustainable path to an electrified future.

James White PhD and Joseph Moniodis PhD | 8th October 2024

Citation: James White and Joseph Moniodis. 2024. “Recharging Responsibility: The Fire Risk Behind Rising Battery Recycling in the U.S.” Carbon Critical. https://carbon-critical.com/battery-fires-in-u-s-recycling-facilities/

References

Battery Recyclers of America. 2023. ‘Key Challenges of Large-Scale Battery Recycling and How to Resolve Them • Battery Recyclers of America’. 25 August 2023. https://www.batteryrecyclersofamerica.com/key-challenges-of-large-scale-battery-recycling-and-how-to-resolve-them/.

CDDl Recycling. 2022. ‘The Shocking Consequences of Improper Battery Disposal!’ 14 December 2022. https://cddlrecycling.co.uk/the-shocking-consequences-of-improper-battery-disposal/.

Ginger Krentz. 2024. ‘How to Prevent Fires in E-Waste Recycling Facilities: Guide’. Re-Source. 2024. https://www.re-source.au/blog/e-waste-facility-fires.

Leal, V. M., J. S. Ribeiro, E. L. D. Coelho, and M. B. J. G. Freitas. 2023. ‘Recycling of Spent Lithium-Ion Batteries as a Sustainable Solution to Obtain Raw Materials for Different Applications’. Journal of Energy Chemistry 79 (April):118–34. https://doi.org/10.1016/j.jechem.2022.08.005.

Massachusetts Department of Fire Services. 2024. ‘After Six Months, New Tracking Tool Identifies 50 Lithium-Ion Battery Fires’. Mass.Gov. 2024. https://www.mass.gov/news/after-six-months-new-tracking-tool-identifies-50-lithium-ion-battery-fires.

Office of Resource Conservation and Recovery. 2021. ‘An Analysis of Lithium-Ion Battery Fires in Waste Management and Recycling’. US Environmental Protection Agency.

Ray Chalmers. 2024. ‘DOE Boosts 17 Battery Recycling Projects with $62 Million’. 2024. https://www.batterytechonline.com/battery-recycling/doe-boosts-17-battery-recycling-projects-with-62-million.

Shelley Mann. 2024. ‘Mitigating Risk, Maximizing Protection’. Waste Today. 2024. https://www.wastetodaymagazine.com/article/protecting-waste-management-facilities-from-lithium-ion-battery-fires/.

US EPA, OLEM. 2019. ‘Used Lithium-Ion Batteries’. Overviews and Factsheets. 16 May 2019. https://www.epa.gov/recycle/used-lithium-ion-batteries.