Handling of lithium-ion batteries onboard –


a big challenge! By Rainer Daniel, FISACON


“The safe handling onboard of lithium-ion batteries is the biggest challenge in recent decades,” said the GM of an international organisation of professional shipping. The largest insurers in the industry confirm that he is right and they are now trying to get this problem under control by all means possible as a matter of urgency. Unfortunately, often, due to a lack of specialist knowledge, without the desired success. It is therefore very important that everyone involved in this topic works together to find workable solutions, be it through training, education or new technical systems.


FISACON started the development of mobile active boxes for the safe handling of lithium-ion batteries in 2017. The pivotal point at the time was a meeting with Special Forces members who asked us if we could develop a lightweight box to handle their batteries - in all operational conditions.


Since we knew that such a box would eventually be transported on an airplane or vessel, we began scientific experiments to determine all relevant data that happens before, during and after a thermal runaway event. Today we have built up one of the most comprehensive databases in this area. Even universities, institutes and insurers are asking us for information.


First, it was important to find a fireproof, explosion-proof, and lightweight composite. In addition to reproducible tests, we also commissioned a company to determine pressure wave loads in the box with the help of numerical simulations. It turned out that impulse pressures of over 7 bar occur. We then developed a special frame for the box with particularly low thermal conductivity.


Due to the very high temperatures in the box of +800°C, we opted for an active extinguishing and cooling system which, controlled by sensors, sprays an environmentally friendly fluid over the battery in the event of a fire. Because the box is waterproof, the battery is flooded and cooled to such an extent that the cells stop responding. This reduces the temperature inside to below 130°C and outside to below 60°C.


A very important topic that is hardly considered with lithium-ion batteries, is the production of hydrofluoric acid (HF) in the event of a fire. It is one of the most aggressive acids of all. It penetrates the skin without pain and causes severe internal injuries that can be fatal.


To prevent HF from escaping, we have developed an exhaust with integrated filter elements that absorbs 100% of this acid. Therefore, HF free smoke comes out of the RACLAN box, which has a temperature of just 80°C. Without this exhaust we measured exhaust gas temperatures of +700°C, which means they will ignite anything flammable in the area.


If the temperature in the RACLAN box rises above 80°C, the external power supply is interrupted and the system reports an alarm. Even a blackout is not a problem, as the box has an emergency power system that provides energy for six months.


The RACLAN Box was the first and so far only one to pass a three-part test (explosion, fire, and filtering of toxic substances) at DMT-TÜV Nord and was certified for it.


FISACON has specialised its developments for the maritime sector. A larger box will be available from October, tailored specifically to water toy batteries, often found on superyachts.


For larger vessels and superyachts the company supplies bespoke cabinets that connect to the onboard fire alarm system and can also accommodate large equipment such as a Seabob with chargers.


About the author | Rainer Daniel has been a security consultant for over three decades. He works worldwide as an expert for critical infrastructure protection and is one of the few specialists who currently develops and manufactures safety solutions for lithium-ion batteries on vessels. He holds several patents in this area. His company FISACON is based in northern Germany.


For more information: https://www.fisacon.com/home.html.


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32