Manufacturers and suppliers of lithium ion cells and batteries can have their products thoroughly tested in a new state-of-the-art test laboratory in Karlstein (Germany), which the batteryuniversity.eu with the support of BMZ Batterien-Montage-Zentrum has put into operation.

In the laboratory, which is among the most advanced of its type in Europe, cells at 0 to 5 V with up to 10/120 A as well as batteries at 0 to 60 V with up to 200 A or to 12 kW can be tested.

According to Sven Bauer, founder of batteryuniversity.eu and managing director of BMZ, it was decided to take this step, not least because of the significantly more stringent transport regulations for lithium ion cells and batteries that came into effect from January 1, 2009. Despite the well-known risks during transport and storage of lithium batteries, some manufacturers, suppliers and transport companies still consciously or unknowingly ignore the regulations. Sven Bauer considers this to be dangerous.

“Lithium in powder or dust form can self ignite at around 20 degrees C room temperature. Lithium as a solid material ignites in the air when the melting point of 179 degrees C is reached; however, once this point is reached a metallic fire that cannot be extinguished develops quickly with temperatures in excess of 2000 degrees C,” said Bauer.
 
Bauer added that lithium also reacts intensively in contact with water. It does not sink, but rather floats on the water surface. This forms a highly inflammable hydrogen gas and highly caustic lithium hydroxide. Explosions in closed rooms could occur by ignition of the hydrogen. Furthermore, the water dissolves lithium hydroxide and takes on its caustic characteristics.

“In addition to due caution in handling of this material, the only protection against these undesired effects are extensive test procedures, in which all possible transport risks are simulated in advance in the laboratory,” commented Bauer.

Since 2003, all lithium cells and batteries, independent of the system and lithium content, must be tested according to special, mandatory safety standards. The accumulators may absolutely not be placed on the market without qualified proof of these tests.

Since the beginning of last year, numerous new regulations for the transport of lithium-based cells and batteries have to be observed. Not only that lithium cells and batteries are now generally classified as “Class 9 Hazardous Materials” (dangerous goods), but also the regulations for registration, packaging, labeling, handling and accompanying documents have to some extent changed significantly. For example, a distinction is now drawn between lithium ion and lithium metal batteries/cells. A decisive factor is also how and in what the respective cell or battery has been packed.

The complexity of the whole issue is shown by the fact that a total of six new UN shipping names with new numbers have been assigned for it: UN 3480 Lithium ion batteries (including lithium polymer batteries), UN 3481 Lithium ion batteries packed with equipment, UN 3481 Lithium ion batteries contained in equipment, UN 3090 Lithium metal batteries (including lithium alloy batteries), UN 3091 Lithium metal batteries packed with equipment and UN 3091 Lithium metal batteries contained in equipment.

General requirement for the approval of lithium cells and/or batteries for transport is, however, always proof of successful tests in accordance with the United Nations "Recommendations on the Transport of Dangerous Goods Manual of Test and Criteria" Part III, subsection 38.3. It is irrelevant whether possible exemptions can be exercised or the cells/batteries are classified as Class 9, and hence must adhere to the hazardous materials regulations in their entirety.

Batteryuniversity.eu with the support of BMZ have so far invested around 1.2 million Euros in personnel and laboratory equipment in order to be able to fully perform all necessary UN Transport Tests for lithium cells and batteries. The investment would hardly ever pay off for companies that are not exclusively involved with the manufacture or assembly of battery packs. In addition, according to Sven Bauer; most of the persons concerned lack the necessary detailed technical knowledge for such tests. It is necessary to have many years of practical experience with different lithium ion technologies in order to assess the safety of battery packs. What happens when this knowledge is missing has been shown in a series of experimental test with third-party products.

“More than 10 percent of the tested batteries did not conform to the current legal safety requirements. We are not only talking here about a fine of up to 50,000 Euros, which could be imposed if regulations are violated. In the event of damage, the responsible persons must also expect that they will be held accountable for substantial destruction of property, severe injury to any person or even, in the worst case, death,” commented Bauer.  Ultimately, for those not wanting to take this potential existence-threatening risk, there is no other alternative to the statutory complex test procedures.

Eight test procedures are compulsory for lithium cells and six test procedures for lithium batteries. 16 to 24 production-ready battery packs are required for the six test procedures, conducted in a certain sequence, on lithium batteries.

Special provisions in the regulations provide "exceptions" or "eased transportation" for lithium ion battery packs with a rating of not more than 100 Wh or cells of not more than 20 Wh and lithium metal battery packs with a lithium content of no more than 2 grams or cells with no more than 1 gram. Subject to compliance with Special Provisions 188 and 230 of ADR/RID, ADNR, IMDG Code and Packing Instructions 965 - 970, Part 2 of IATA Dangerous Goods Regulations, transportation of these lithium cells and batteries is not subject to other rules and regulations.

In order to be authorized for "eased transportation" - in other words, without having to fully comply with the dangerous goods regulations - packages must be labeled with a special label including e.g. an emergency telephone number. Each consignment must be accompanied with a document with an indication that the package contains lithium ion or lithium metal cells or batteries, a flammability hazard exists if the package is damaged and special procedures should be followed in the event the package is damaged, to include inspection and repacking if necessary.

If the thresholds of 20 Wh/100 Wh or 1 g/2 g lithium content are exceeded, the lithium ion cells and batteries must always be transported as dangerous goods of Class 9, Packing Group II in compliance with the packaging standards.

“100% safety for the transport of lithium ion battery packs can never be achieved. However, with our test laboratory we have at least created conditions to come as close as possible to this goal,” suggested Bauer.


The batteryuniversity.eu is exhibiting at electronica 2010 in Hall B2, Booth 474.

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