How to Safeguard Against Thermal Runaway in Lithium-Ion Renewable Energy Storage Facilities

Lithium-ion batteries have become the backbone of renewable energy storage, offering high energy density and efficiency. However, they also pose risks that must be addressed in planning, particularly the risk of thermal runaway: a self-sustaining reaction that can lead to fires or explosions. Understanding the causes, prevention strategies, and emergency response protocols is critical for engineers and renewable energy providers in their quest to provide greener alternatives.

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Understanding Thermal Runaway

Thermal runaway occurs when a lithium-ion battery generates more heat than it can dissipate, leading to a rapid temperature increase. This process typically follows these stages:

1. Initial Overheating – Caused by overcharging, external heat exposure, or internal defects
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2. Electrolyte Breakdown – The flammable electrolyte, the organic material that provides the charge, decomposes, releasing gases
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3. Pressure Build-up – Gas accumulation increases internal pressure, deforming the battery casing
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4. Combustion or Explosion – If the casing ruptures, ignition can occur, leading to fire or explosion

Because large-scale LIB storage facilities utilize the modularity of the technology to build packs and modules with high storage capacity, thermal runaway has the potential of damaging entire power plants, if it occurs.

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Causes of Thermal Runaway

Several factors can contribute to thermal runaway:

• Overcharging – Charging beyond the recommended voltage increases internal heat

• Short Circuits – Internal or external short circuits create uncontrolled current flow

• Mechanical Damage – Punctures or deformation compromise battery integrity

• High Ambient Temperatures – Excessive heat accelerates electrolyte decomposition

Due to the extreme volatility and toxicity of thermal runaway in lithium-ion technology, it is imperative that all fire suppression safety measures be in working order. Although still under investigation, it was reported that Monterey County, California’s Moss Landing Power Plant fire spread, in part, due to a malfunctioning fire suppression system that failed to activate. However, the fire never reached beyond the boundaries of the facility.

Monterey-area residents filed suit in February of 2025, accusing Vistra Energy, LG Energy Solutions, and Pacific Gas & Electric of failure to maintain adequate fire safety at the facility, according to reporting in the Los Angeles Times.

That said, LIB storage facilities are reported to be safe, overall, and the American Clean Power Association reports that utility-scale storage capacity had grown to seven times its 2020 capacity by the end of 2023. So it is crucial that power plant engineers and renewable energy providers take all necessary steps to keep the risk of thermal runaway at bay.

Preventative Measures

Below is a partial list of the measures LIB storage system facilities managers and energy providers utilize to safeguard against thermal runaway.

1. Battery Management Systems (BMS)

• A robust BMS monitors voltage, temperature, and current to prevent unsafe conditions

2. Thermal Management Solutions

• Implementing cooling systems, phase-change materials, and heat sinks can dissipate excess heat

3. Proper Installation and Maintenance

• Ensure adequate spacing between battery cells to prevent heat transfer
• Regularly inspect batteries for swelling, discoloration, or leaks

4. Fire Suppression Systems

• Deploying fire-resistant enclosures and automatic suppression systems can mitigate damage

Emergency Response to Thermal Runaway Events

The #1 rule according to the International Association of Fire Chiefs is NOT to attempt to enter any Energy Storage System Facility (ESS) during a fire, due to the extreme heat thermal runaway causes and the toxic fumes that can be released. That said, there are specific safety protocols that ESS facilities managers and utility providers can utilize to lessen a fire's impact.

1. Detection and Early Intervention

• Use thermal imaging and gas sensors to detect early signs of thermal runaway
• Isolate affected battery modules to prevent propagation

2. Fire Suppression Techniques

• Water Mist Systems – Effective for cooling and suppressing lithium-ion battery fires
• Dry Chemical Agents – Specialized extinguishing agents can neutralize battery fires

3. Evacuation and Containment

• Establish clear evacuation protocols for personnel safety
• Contain fires using fire-resistant barriers to prevent spread

GPRS and SiteMap: Supporting Renewable Energy Safety

GPRS can play a crucial role in helping renewable energy companies ensure the safety and efficiency of their projects. Through advanced ground penetrating radar (GPR) and electromagnetic (EM) locating technology, GPRS helps identify underground infrastructure, reducing risks associated with battery storage facility installations.

SiteMap® (patent pending), powered by GPRS, provides accurate, aggregated site data, enabling engineers to access real-time infrastructure information. This single source of truth enhances safety planning and risk mitigation for lithium-ion battery storage facilities.

Thermal runaway in lithium-ion battery storage facilities presents challenges for renewable energy providers. By implementing advanced monitoring systems, thermal management solutions, and fire suppression techniques, engineers can safeguard against catastrophic failures. The American Clean Power Association reports that only 20 fire-related incidents have occurred at ESS facilities in the last decade, while the industry has seen 25,000% growth.

Leveraging GPRS and SiteMap may ensure comprehensive site visualization, enhancing safety and operational efficiency.

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