IDEAS home Printed from https://ideas.repec.org/a/eee/appene/v385y2025ics0306261925002752.html
   My bibliography  Save this article

Experimental and simulation study on internal thermal runaway development drives venting and flammable gas risk evaluate of Lithium-ion battery

Author

Listed:
  • Wang, Peiben
  • Xu, Chengshan
  • Huang, Jingru
  • Zhang, Mengqi
  • Jiang, Fachao
  • Feng, Xuning

Abstract

Heat generation and gas venting are the primary characteristics of thermal runaway in lithium-ion batteries. The convective and diffusive properties of the venting gas pose significant challenges for hazard analysis and safety assessment of thermal runaway venting. Quantifying the potential combustion risk associated with the vented flammable gases is crucial for ensuring battery safety. In this study, we investigated the thermal runaway venting behavior of Li(Ni0.8Co0.1Mn0.1)O2 prismatic cells through experimental and simulation methods. The results indicate that the battery has discharged 4.83 mol of combustible gas. The gas composition mainly consists of H2 (20.5 %), C2H4 (12.5 %), CH4 (5.5 %), CO (27.9 %), and CO2 (28.6 %). Gas combustion account for 19.6 % of the total venting time. We propose an internal thermal runaway progression-driven venting and flammable gas risk evaluation model. This model assesses the combustion risk of flammable gases during the venting process and identifies high-risk areas where gas combustion may occur, specifically the area 1 m above the safety valve, which exhibits the highest risk for flammable gas combustion and possesses the greatest explosive power. This research is poised to make a significant contribution to the safe design of battery pack systems.

Suggested Citation

  • Wang, Peiben & Xu, Chengshan & Huang, Jingru & Zhang, Mengqi & Jiang, Fachao & Feng, Xuning, 2025. "Experimental and simulation study on internal thermal runaway development drives venting and flammable gas risk evaluate of Lithium-ion battery," Applied Energy, Elsevier, vol. 385(C).
  • Handle: RePEc:eee:appene:v:385:y:2025:i:c:s0306261925002752
    DOI: 10.1016/j.apenergy.2025.125545
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0306261925002752
    Download Restriction: Full text for ScienceDirect subscribers only

    File URL: https://libkey.io/10.1016/j.apenergy.2025.125545?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Feng, Xuning & Lu, Languang & Ouyang, Minggao & Li, Jiangqiu & He, Xiangming, 2016. "A 3D thermal runaway propagation model for a large format lithium ion battery module," Energy, Elsevier, vol. 115(P1), pages 194-208.
    2. Wang, Yu & Ren, Dongsheng & Feng, Xuning & Wang, Li & Ouyang, Minggao, 2022. "Thermal runaway modeling of large format high-nickel/silicon-graphite lithium-ion batteries based on reaction sequence and kinetics," Applied Energy, Elsevier, vol. 306(PA).
    3. Wang, Gongquan & Kong, Depeng & Ping, Ping & He, Xiaoqin & Lv, Hongpeng & Zhao, Hengle & Hong, Wanru, 2023. "Modeling venting behavior of lithium-ion batteries during thermal runaway propagation by coupling CFD and thermal resistance network," Applied Energy, Elsevier, vol. 334(C).
    4. Kuang, Yucheng & He, Boshu & Wang, Chaojun & Tong, Wenxiao & He, Di, 2021. "Numerical analyses of MILD and conventional combustions with the Eddy Dissipation Concept (EDC)," Energy, Elsevier, vol. 237(C).
    5. Ostanek, Jason K. & Li, Weisi & Mukherjee, Partha P. & Crompton, K.R. & Hacker, Christopher, 2020. "Simulating onset and evolution of thermal runaway in Li-ion cells using a coupled thermal and venting model," Applied Energy, Elsevier, vol. 268(C).
    6. Ren, Dongsheng & Feng, Xuning & Lu, Languang & He, Xiangming & Ouyang, Minggao, 2019. "Overcharge behaviors and failure mechanism of lithium-ion batteries under different test conditions," Applied Energy, Elsevier, vol. 250(C), pages 323-332.
    7. Kang, Sungwook & Kwon, Minjae & Yoon Choi, Joung & Choi, Sengkwan, 2023. "Full-scale fire testing of battery electric vehicles," Applied Energy, Elsevier, vol. 332(C).
    8. Jia, Zhuangzhuang & Song, Laifeng & Mei, Wenxin & Yu, Yin & Meng, Xiangdong & Jin, Kaiqiang & Sun, Jinhua & Wang, Qingsong, 2022. "The preload force effect on the thermal runaway and venting behaviors of large-format prismatic LiFePO4 batteries," Applied Energy, Elsevier, vol. 327(C).
    9. Xu, Chengshan & Wang, Huaibin & Jiang, Fachao & Feng, Xuning & Lu, Languang & Jin, Changyong & Zhang, Fangshu & Huang, Wensheng & Zhang, Mengqi & Ouyang, Minggao, 2023. "Modelling of thermal runaway propagation in lithium-ion battery pack using reduced-order model," Energy, Elsevier, vol. 268(C).
    10. Wei, Gang & Huang, Ranjun & Zhang, Guangxu & Jiang, Bo & Zhu, Jiangong & Guo, Yangyang & Han, Guangshuai & Wei, Xuezhe & Dai, Haifeng, 2023. "A comprehensive insight into the thermal runaway issues in the view of lithium-ion battery intrinsic safety performance and venting gas explosion hazards," Applied Energy, Elsevier, vol. 349(C).
    11. Jin, Changyong & Sun, Yuedong & Wang, Huaibin & Zheng, Yuejiu & Wang, Shuyu & Rui, Xinyu & Xu, Chengshan & Feng, Xuning & Wang, Hewu & Ouyang, Minggao, 2022. "Heating power and heating energy effect on the thermal runaway propagation characteristics of lithium-ion battery module: Experiments and modeling," Applied Energy, Elsevier, vol. 312(C).
    12. Qin, Peng & Jia, Zhuangzhuang & Wu, Jingyun & Jin, Kaiqiang & Duan, Qiangling & Jiang, Lihua & Sun, Jinhua & Ding, Jinghu & Shi, Cheng & Wang, Qingsong, 2022. "The thermal runaway analysis on LiFePO4 electrical energy storage packs with different venting areas and void volumes," Applied Energy, Elsevier, vol. 313(C).
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Zhang, Yue & Song, Laifeng & Tian, Jiamin & Mei, Wenxin & Jiang, Lihua & Sun, Jinhua & Wang, Qingsong, 2024. "Modeling the propagation of internal thermal runaway in lithium-ion battery," Applied Energy, Elsevier, vol. 362(C).
    2. Wang, Gongquan & Ping, Ping & Peng, Rongqi & Lv, Hongpeng & Zhao, Hengle & Gao, Wei & Kong, Depeng, 2023. "A semi reduced-order model for multi-scale simulation of fire propagation of lithium-ion batteries in energy storage system," Renewable and Sustainable Energy Reviews, Elsevier, vol. 186(C).
    3. Zhang, Pengfei & Chen, Haipeng & Yang, Kangbo & Lu, Yiji & Huang, Yuqi, 2024. "Accelerated computational strategies for multi-scale thermal runaway prediction models in Li-ion battery," Energy, Elsevier, vol. 305(C).
    4. Li, Kuijie & Gao, Xinlei & Wang, Shengshi & Peng, Shijian & Zhang, Weixin & Wu, Weixiong & Wang, Huizhi & Liu, Peng & Han, Xuebing & Cao, Yuan-cheng & Wen, Jinyu & Cheng, Shijie & Ouyang, Minggao, 2024. "Comparative analysis of multidimensional signals evolution in prismatic and pouch LiFePO4 batteries under thermal abuse," Applied Energy, Elsevier, vol. 372(C).
    5. Wei, Gang & Huang, Ranjun & Zhang, Guangxu & Jiang, Bo & Zhu, Jiangong & Guo, Yangyang & Han, Guangshuai & Wei, Xuezhe & Dai, Haifeng, 2023. "A comprehensive insight into the thermal runaway issues in the view of lithium-ion battery intrinsic safety performance and venting gas explosion hazards," Applied Energy, Elsevier, vol. 349(C).
    6. Li, Kuijie & Gao, Xinlei & Peng, Shijian & Wang, Shengshi & Zhang, Weixin & Liu, Peng & Wu, Weixiong & Wang, Huizhi & Wang, Yu & Feng, Xuning & Cao, Yuan-cheng & Wen, Jinyu & Cheng, Shijie & Ouyang, M, 2024. "A comparative study on multidimensional signal evolution during thermal runaway of lithium-ion batteries with various cathode materials," Energy, Elsevier, vol. 300(C).
    7. Li, Kuijie & Chen, Long & Gao, Xinlei & Lu, Yao & Wang, Depeng & Zhang, Weixin & Wu, Weixiong & Han, Xuebing & Cao, Yuan-cheng & Wen, Jinyu & Cheng, Shijie & Ouyang, Minggao, 2024. "Implementing expansion force-based early warning in LiFePO4 batteries with various states of charge under thermal abuse scenarios," Applied Energy, Elsevier, vol. 362(C).
    8. Zhou, Hanwei & Alujjage, Anuththara S. & Terese, Maria & Fear, Conner & Joshi, Tapesh & Rikka, Vallabha Rao & Jeevarajan, Judith A. & Mukherjee, Partha P., 2025. "Effect of fast charging on degradation and safety characteristics of lithium-ion batteries with LiFePO4 cathodes," Applied Energy, Elsevier, vol. 377(PA).
    9. He, C.X. & Liu, Y.H. & Huang, X.Y. & Wan, S.B. & Lin, P.Z. & Huang, B.L. & Sun, J. & Zhao, T.S., 2024. "A reduced-order thermal runaway network model for predicting thermal propagation of lithium-ion batteries in large-scale power systems," Applied Energy, Elsevier, vol. 373(C).
    10. E, Jiaqiang & Xiao, Hanxu & Tian, Sicheng & Huang, Yuxin, 2024. "A comprehensive review on thermal runaway model of a lithium-ion battery: Mechanism, thermal, mechanical, propagation, gas venting and combustion," Renewable Energy, Elsevier, vol. 229(C).
    11. Jin, Changyong & Sun, Yuedong & Wang, Huaibin & Zheng, Yuejiu & Wang, Shuyu & Rui, Xinyu & Xu, Chengshan & Feng, Xuning & Wang, Hewu & Ouyang, Minggao, 2022. "Heating power and heating energy effect on the thermal runaway propagation characteristics of lithium-ion battery module: Experiments and modeling," Applied Energy, Elsevier, vol. 312(C).
    12. Luo, Pan & Gao, Kai & Hu, Lin & Chen, Bin & Zhang, Yuanjian, 2024. "Adaptive hybrid cooling strategy to mitigate battery thermal runaway considering natural convection in phase change material," Applied Energy, Elsevier, vol. 361(C).
    13. Cheng, Zhixiang & Min, Yuanyuan & Qin, Peng & Zhang, Yue & Li, Junyuan & Mei, Wenxin & Wang, Qingsong, 2025. "A distributed thermal-pressure coupling model of large-format lithium iron phosphate battery thermal runaway," Applied Energy, Elsevier, vol. 378(PB).
    14. Jia, Zhuangzhuang & Song, Laifeng & Mei, Wenxin & Yu, Yin & Meng, Xiangdong & Jin, Kaiqiang & Sun, Jinhua & Wang, Qingsong, 2022. "The preload force effect on the thermal runaway and venting behaviors of large-format prismatic LiFePO4 batteries," Applied Energy, Elsevier, vol. 327(C).
    15. Chen, Long & Li, Kuijie & Cao, Yuan-cheng & Feng, Xuning & Wu, Weixiong, 2025. "Multidimensional signal fusion strategy for battery thermal runaway warning towards multiple application scenarios," Applied Energy, Elsevier, vol. 377(PB).
    16. Huang, Zhiliang & Wang, Huaixing & Zou, Wei & Zhang, Rongchuan & Wang, Yuhan & Chen, Jie & Wu, Shengben, 2024. "An online evaluation model for mechanical/thermal states in prismatic lithium-ion batteries under fast charging/discharging," Energy, Elsevier, vol. 302(C).
    17. Mao, Binbin & Zhao, Chunpeng & Chen, Haodong & Wang, Qingsong & Sun, Jinhua, 2021. "Experimental and modeling analysis of jet flow and fire dynamics of 18650-type lithium-ion battery," Applied Energy, Elsevier, vol. 281(C).
    18. Chen, Jie & Ren, Dongsheng & Hsu, Hungjen & Wang, Li & He, Xiangming & Zhang, Caiping & Feng, Xuning & Ouyang, Minggao, 2021. "Investigating the thermal runaway features of lithium-ion batteries using a thermal resistance network model," Applied Energy, Elsevier, vol. 295(C).
    19. He, C.X. & Yue, Q.L. & Chen, Q. & Zhao, T.S., 2022. "Modeling thermal runaway of lithium-ion batteries with a venting process," Applied Energy, Elsevier, vol. 327(C).
    20. Zhang, Yue & Cheng, Siyuan & Mei, Wenxin & Jiang, Lihua & Jia, Zhuangzhuang & Cheng, Zhixiang & Sun, Jinhua & Wang, Qingsong, 2023. "Understanding of thermal runaway mechanism of LiFePO4 battery in-depth by three-level analysis," Applied Energy, Elsevier, vol. 336(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:appene:v:385:y:2025:i:c:s0306261925002752. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/405891/description#description .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.