EWJ FEB 59 2025 web - Flipbook - Page 58
Process Safety Implications of
Lithium-Ion Battery Development
A case study of work undertaken by Sohail Khan, Consultant - Finch Consulting
With the growing demand for electric vehicles and energy storage, our client, a global leader in
sustainable technologies, expanded their research and development (R&D) into lithium-ion battery
technology.
The before:
The project involved testing new battery compositions
and optimising manufacturing processes for large-scale
production. However, lithium-ion batteries present
several safety challenges due to the use of flammable
electrolytes and the potential generation of explosive
gases during battery failure or stress testing. The client
recognised the need to manage these risks, particularly
under the Dangerous Substances and Explosive
Atmospheres Regulations (DSEAR), which govern
potentially explosive atmospheres in the workplace.
The result:
Following the risk assessment and implementation of
control measures, the client significantly reduced the
potential for explosive atmospheres in their testing
and manufacturing environments. An Explosion
Protection Document (EPD) was developed, outlining
the control measures and safety protocols in place to
manage the risks. By proactively addressing the
DSEAR requirements, the client not only improved
safety but also ensured regulatory compliance, reducing liability and strengthening their position as an
industry leader in battery technology. Moreover, the
team’s enhanced understanding of DSEAR and
potentially explosive atmospheres in their process
ensured their designs for production were safe and
compliant with DSEAR.
The during:
A comprehensive DSEAR risk assessment was
conducted to ensure workers and the facility’s safety.
This risk assessment identified several hazards: the potential release of flammable gases during overcharging
or thermal runaway scenarios, the risk of dust explosions from metal powders, and the danger of electrostatic discharge (ESD) igniting these substances. To
mitigate these risks, we recommended that our client
implement multiple safety layers, including redesigned test chambers, gas detection systems, and
improved ventilation. The battery testing protocols
were adjusted to include remote monitoring, minimising employee exposure to high-risk areas during
critical testing.
This case highlights the importance of integrating
DSEAR and process safety management into the development and manufacturing of lithium-ion batteries, ensuring both innovation and safety in potentially
hazardous environments.
If you need any help with battery technologies,
please don’t hesitate to contact
sohail.khan@finch-consulting.com.
About Finch Consulting
Helping businesses of every size reduce their risks.
We protect, guide and elevate your business. No matter what challenges it faces. Working with our community of experts, together we will reduce risks, boost
recovery and embed in you the confidence to make
the company flourish. Our versatility is limitless. We’ve
helped clients spanning many sectors, from manufacturing to legal, mining to leisure, around the world.
Clients trust our experts because they know what
matters to them.
That’s why they return. Many clients partner with us
repeatedly to keep their firms on the right track.
Our culture
Our people are Finch. Empathetic, honest
and adaptable, each works seamlessly together or
independently to achieve the required results.
Our goal
Our main aim is – naturally – to reduce risks for
clients. Working with us achieves this through the latest asset management, process safety management
and health and safety management techniques.
We’re committed to continually upskilling staff with
relevant training, education and professional memberships to keep them at the top of their game.
As well as helping clients, the team supports good
causes through fundraising.
Here at Finch, growth is also important to us.
We are investing in our people, processes and marketing to build from a small to a medium professional
service business which delivers added value.
In 2022, we collected an incredible £14,000 for the
local mental health charity Burton & District Mind.
Our reputation
We have more than 30 years of experience in making
businesses better.
EXPERT WITNESS JOURNAL
www.finch-consulting.com
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