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The Dos and Don’ts of Shipping Lithium Batteries

DOT Safety Training for Shipping Lithium Batteries

We’ve all heard of lithium batteries… after all, we use them in all our modern tech devices and even in our cars. But have you ever realized that lithium batteries are categorized as hazardous cargo due to their higher energy density and flammable electrolytes?

According to the PHMSA, “lithium batteries pose a fire hazard, even when they are no longer useful in consumer equipment/products. Damaged, defective, or recalled batteries have greater potential than undamaged lithium batteries to short circuit, release heat, or even cause a fire.” Thus, the PHMSA advises that appropriate precautions be taken when shipping new lithium batteries or when shipping used, damaged, or old lithium batteries for disposal or recycling.

Considering the high possibility of the hazards associated with shipping lithium batteries, the U.S. Department of Transportation (DOT) and the International Air Transport Association (IATA) have both enacted strict regulations for the transportation of lithium batteries including packaging, marking, and specific labeling requirements.

What is a Lithium Battery?

The term “lithium battery” refers to one or more lithium cells that are electrically connected. A cell is a single encased electrochemical unit, while a battery consists of multiple electrically connected component cells. A battery can also only be made up of a single cell, such as the common AA, C, or coin cell.

A lithium battery is like other types of battery. The lithium battery cells contain a positive electrode, a negative electrode, a separator, and an electrolyte solution. Atoms or molecules with a net electric charge (ions) are transferred from a positive electrode to a negative electrode through an electrolyte solution. Lithium cells store and release power by converting chemical potential energy into electrical energy using lithium ions or lithium metal. Electrolyte solutions allow ions to flow freely between the electrodes.

So, what should manufacturers of lithium batteries and consumer product manufacturers using pre-installed lithium batteries in products such as watches, smartphones, tablets, laptops, cars, and various other devices and equipment know about the transportation of lithium batteries?

Understanding the dos and don’ts when shipping lithium batteries is important to adhere to the regulatory requirements while safeguarding the shipment, people, and environment from fire and explosion hazards. Thus, manufacturers of lithium batteries and those using lithium batteries as a component of their products must first identify the type and size of the lithium battery being transported, the categorization of lithium batteries, how the lithium battery will be transported, and the mode of transportation to be used.

Let’s check these points individually to gain a better understanding of the lithium battery transportation regulations which will guide on the dos and don’ts when shipping lithium batteries.

#1 Understand the type of lithium battery being shipped

Manufacturers of lithium batteries and producers of other goods utilizing lithium batteries as their power source must first identify the type of lithium battery – “lithium ion battery” or “lithium metal battery”.

What Is the Difference Between Lithium-ion and Lithium Metal Batteries?

Lithium metal batteries contain metallic lithium and are primarily non-rechargeable. They have lithium metal or lithium compounds as an anode. Included in this group are lithium alloy batteries.

Lithium-ion batteries are rechargeable, and lithium is only present in the electrolyte in the ionic form. Included in the lithium-ion category are lithium polymer batteries. Lithium batteries are sometimes abbreviated as Li-ion batteries.

(IATA, 2021)

These two types of batteries are governed by different shipping regulations and hence, identifying the type of lithium battery being shipped will enable the appropriate regulations to be followed.

Lithium Ion Batteries

Lithium Metal Batteries

#2 Know the size of the lithium battery

The lithium battery size also impacts the dos and don’ts of shipping lithium batteries. The DOT Hazardous Materials Regulations (HMR) specify the labeling and marking requirements for not only the different types of lithium batteries but also for the different sizes. Furthermore, the size of the lithium battery can also impact the decision on the method of transportation – highway, rail, aircraft, or vessel.

Lithium battery size is measured in Watt Hour (Wh) for lithium ion batteries and kilograms (kg) for lithium metal batteries.

This leads us to point #3, which considers the transportation of lithium batteries in terms of energy density and the classification as applied by the DOT HMR.

#3 Know the lithium battery classification

The regulations classify lithium batteries based on their size as ‘Fully Regulated’ or ‘Excepted’. Lithium Batteries of a higher energy density would fall within the fully-regulated category and be subject to stricter regulations while lower energy density lithium batteries may gain excepted status and have lesser rules to comply with during transportation. The categorization status of lithium batteries also impacts the mode of transportation that can be used in the transfer of goods from one destination to another.

Fully regulated lithium ion/metal cells or batteries for the purposes of DOT regulations include:

Lithium ion cell or battery

Lithium metal cell or battery

· A cell with a Watt-hour rating greater than 20 Wh; and

· A battery with a Watt-hour rating greater than 100 Wh.

· A cell with a lithium content greater than 1g; and

· A battery with a lithium content greater than 2g.

Here’s a good example of the regulatory requirements changing according to the categorization of lithium batteries for air shipments of stand-alone lithium cells and batteries.

As of January 1, 2022, according to IATA Packing Instructions 965 (lithium ion batteries) and 968 (lithium metal batteries), all shipments of stand-alone lithium cells and batteries will be considered fully regulated and will no longer be subject to Section II provisions for excepted lithium cells and batteries. Stand-alone lithium cells and batteries can now be shipped under Section IA and IB of PI 965 and 968.

#4 How will the lithium battery or batteries be shipped

Another important aspect of shipping lithium batteries is to identify how the lithium battery will be shipped. For instance, will the lithium battery be shipped separately (stand-alone), with the machine or equipment (meaning in the same outer packaging as the equipment), or inside the device?

The way that the lithium batteries are going to be packed, labeled, marked, and the mode of transportation that can be used is dependent on how the lithium ion or metal batteries are going to be shipped.

Stand-Alone Lithium Batteries

Lithium Battery with Equipment

Lithium Battery Inside the Device

Important Note for air shipments of stand-alone lithium cells and batteries:

#5 Mode of Transportation – Highway, Rail, Air, or Vessel

The mode of transportation also plays an important aspect in the dos and don’ts of shipping lithium batteries due it their capacity to explode and the other unique hazards associated with lithium battery transportation. Thus, depending on the mode of transporting lithium batteries; either by air, water, or ground, will impact the regulations that must be followed by manufacturers. It is worth noting that due to the size and categorization of the lithium battery, some manufacturers may face limited options for the transportation of lithium batteries.

For example, Lithium-ion cells that exceed 20 Wh but do not exceed 60 Wh are forbidden for transport aboard aircraft and vessels. Thus, the only mode of transportation available are highway and rail.

Training for Shipping Lithium Ion/Lithium Metal Cells or Batteries

To fully understand the regulatory requirements of shipping lithium cells and batteries, we have several shipping lithium battery training courses that comply with the DOT HMR. For comprehensive training, enroll in our online DOt, IATA, IMDG Shipping Lithium Batteries - Advances General Awareness Training course.

To know more about our group virtual or in-person training options as well as our SCORM package for the Shipping Lithium Batteries courses, call us or email us and we will get back to you within 24-hours!

Reference:

IATA. (2021, August 13). What to know about how to ship lithium batteries? Website. https://www.iata.org/en/publications/newsletters/iata-knowledge-hub/what-to-know-about-how-to-ship-lithium-batteries/