Safeguarding lithium-ion battery gigafactories against fire hazards
No facility wants to think about the potential of a fire, but every facility needs to be ready in case there is one. Manufacturing facilities in particular need to be mindful – and prepared – for fire incidents given the potentially hazardous materials used in the manufacturing process or the items being made.
The risk of fire is especially acute in the gigafactories that are starting to proliferate around the world. Originally coined by Tesla Inc., the term “gigafactory” refers to a massive manufacturing plant dedicated to producing rechargeable batteries on a large scale, specifically for use in electric vehicles. While Tesla popularized the concept, the term has since been embraced more broadly to describe any factory that mass-produces batteries for various applications. Overall, the global gigafactory market is expected to grow at an annual compound rate of 18.03% from 2023 to 2028 [i] This growth is due to greater electric vehicle (EV) adoption and the increasing demand for lithium-ion (Li-ion) batteries, which are used to power everything from cellphones to toys to energy storage systems. Global EV sales are projected to hit around 17 million in 2024 [ii], accounting for more than one in five cars sold worldwide. As a result, investments in gigafactories are expected to increase from $131 billion in 2022 to around $300 billion by 2030.[iii]
Gigafactories primarily produce cells and battery modules and house numerous raw materials that can potentially spontaneously combust. What’s more, in a gigafactory – and in other specialized manufacturing facilities – there may be off-gases emitted that are not detected by traditional fire detection devices. That is why a multipronged, integrated strategy for fire safety is needed to effectively address risks.
Specialized facilities require a specialized approach
Let’s take a closer look at a gigafactory where Li-ion batteries are produced. Best practices for gigafactory fire and life safety prescribe a two-pronged approach to early detection and mitigation of fire events:
1. Use aspirating smoke detection, like the Honeywell VESDA (Very Early Smoke Detection Apparatus), to actively pull air from throughout a facility and continuously test for the presence of the earliest nascent smoke molecules from ignition of traditional (non-battery) materials and assets.
2. Deploy tools, like the Honeywell Li-ion Tamer solution, for early detection system of the most nascent off-gas molecules from battery material (including electrolyte) breakdown, to help prevent thermal runaway before it starts.
When it comes to fire and life safety, the time to detect an event is when it is just a wisp of smoke. Advanced detection technology is crucial to help you investigate and respond early, minimizing damage and disruption.
Honeywell VESDA aspirating smoke-detection solutions feature capabilities that offer increased sensitivity, lower power consumption and reduced Total Cost of Ownership (TCO).[iv] Core to these solutions is the continuous air sampling that delivers early warning of an impending fire hazard from combustion of non-battery materials. The smoke detectors provide the critical time needed to investigate an alarm and initiate an appropriate response to prevent injury, property damage, or business disruption.
Early smoke detection is not the only fire concern in a gigafactory. There are significant fire risks associated with the electrolytes used in Li-ion cells. Organic solvents in the electrolytes may overheat and emit off-gasses undetectable by most traditional fire systems. Often, a problem is not discovered until an event known as “thermal runaway” has already been initiated, resulting in high temperature fires and the release of potentially hazardous gases. Thermal runaway is often a point of no return, causing difficult-to-extinguish fires where the only course of action is to allow the battery materials to burn to exhaustion (and thereby potentially spreading the fire).
The unique risks that accompany the production of Li-ion batteries require advanced detection solutions that are sensitive to the changes that occur when a battery’s materials begin to fail. Typically, a mixture of gases is emitted from the failing battery and early detection of this combustible cocktail is critical. The Honeywell Li-ion Tamer solution detects catastrophic battery failures very early, in the pre-smoke stage. Li-ion Tamer is a plug-and-play system that improves safety by sensing the off-gassing that precedes smoke and eventually thermal-runaway battery failures much earlier than smoke detection or traditional gas detection would.
An integrated, end-to-end fire solution delivers comprehensive safety
Let’s consider a scenario where a fire alarm is triggered in a gigafactory. When this happens, a sequence of events occurs. Strobes start flashing, sprinklers activate, and speakers deliver an audible message notifying plant workers to prepare for evacuation.
If the facility has implemented an integrated approach, it could initiate other critical actions automatically and simultaneously per the factory’s standard operating procedures. The HVAC system for venting and exhausting air will shut down. Specific exhaust fans will turn on to start removing smoke from the area. Dampers will close to contain the fire within the area where it is burning. Overhead doors will also close.
Additionally, once an alarm is triggered, integrated response features like direct alarm communication to dispatchers and first responders make sure that help is rapidly mobilized with full situational awareness.
An integrated approach also means that facility managers have real-time dashboards and the ability to centrally monitor and control fire detection, suppression, communications and emergency protocols across the entire facility. This level of advanced, connected protection can give gigafactories a comprehensive command of fire-risk management and the ability to rapidly address any fire-related emergencies that take place.
Honeywell’s approach
Honeywell’s end-to-end approach to fire and life safety includes cutting-edge technologies, expert consultation, tailored design, strategic third-party procurement, professional installation, and ongoing service and support. Our solutions are designed to enhance the safety of your facility and your people, to help improve productivity and uptime while reducing risks. With Honeywell’s integrated and holistic approach to fire safety, gigafactories can operate with peace of mind, knowing their facilities and personnel are protected.
Connect with a Honeywell expert today to learn how to improve the fire and life safety of your facility.
[i] GME, Global Gigafactory Market Size [Accessed June 19, 2024]
[ii] IEA, Global EV Outlook 2024 [Accessed June 19, 2024]
[iii] Frost & Sullivan, Investments in Gigafactories, coupled with Industry 5.0 Technologies, to Enable Lithium-ion Battey Manufacturers to Keep Pace with Electric Vehicle Boom [Accessed June 19, 2024]
[iv] Honeywell, Critical Protection for Critical Infrastructure, Feb 2022 [Accessed Sep 10, 2024]
