Self-reactive rating of thermal runaway hazards on 18650 lithium-ion batteries

Vent sizing package 2 (VSP2) was used to measure the thermal hazard and runaway characteristics of 18650 lithium-ion batteries, which were manufactured by Sanyo Electric Co., Ltd. Runaway reaction behaviors of these batteries were obtained: 50% state of charge (SOC), and 100% SOC. The tests evaluated the thermal hazard characteristics, such as initial exothermic temperature (T ₀), self-heating rate (dT?dt ^?1), pressure-rise rate (dP?dt ^?1), pressure temperature profiles, maximum temperature, and pressure which were observed by adiabatic calorimetric methodology via VSP2 using customized test cells. The safety assessment of lithium-ion cells proved to be an important subject. The maximum self-heating rate (dT?dt ^?1)_max and the largest pressure-rise rate (dP?dt ^?1)_max of Sanyo 18650 lithium-ion battery of 100% SOC were measured to be 37,468.8???C?min^?1 and 10,845.6?psi?min^?1, respectively, and the maximum temperature was 733.1???C. Therefore, a runaway reaction is extremely serious when a lithium-ion battery is exothermic at 100% SOC. This result also demonstrated that the thermal VSP2 is an alternative method of thermal hazard assessment for battery safety research. Finally, self-reactive ratings on thermal hazards of 18650 lithium-ion batteries were studied and elucidated to a deeper extent.     

Thermal runaway features of 18650 lithium-ion batteries for LiFePO4 cathode material by DSC and VSP2

In view of availability, accountability, and applicability, LiFePO₄ cathode material has been confirmed to be better than LiCoO₂ cathode material. Nevertheless, few related researches were conducted for thermal runaway reaction of the LiFePO₄ batteries. In this study, vent sizing package 2 (VSP2) and differential scanning calorimetry were employed to observe the thermal hazard of 18650 lithium-ion batteries and their content??LiFePO₄ cathode material, which were manufactured by Commercial Battery, Inc. Two states of the batteries were investigated, which was charged to 3.6?V (fully charged) and 4.2?V (overcharged), respectively, and important parameters were obtained, such as self-heating rate (dT?dt ^?1), pressure-rise rate (dP?dt ^?1), and exothermic onset temperature (T ₀). The results showed that T ₀ for fully charged is about 199.94?°C and T _max is about 243.23?°C. The entire battery for LiFePO₄ cathode material is more stable than other lithium-ion batteries, and an entire battery is more dangerous than a single cathode material. For process loss prevention, the data of battery of VSP2 test were applied as reference for design of safer devices.     

Thermal hazard evaluation of tert-butyl peroxide using non-isothermal and adiabatic calorimetric approaches

Tert-butyl peroxide (TBPO), is a typical organic peroxides (OPs),which is widely applied as initiator in poly-glycidyl methacrylate (PGMA) reaction, and is employed to provide a free-radical in frontal polymerization, and which has also caused many thermal runaway reactions and explosions worldwide. To find an unknown and insufficient hazard information for an energetic material, differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2) were employed to detect the fundamental thermokinetic parameters involving the exothermic onset temperature (T ₀), heat of decomposition (??H _d), temperature rise rate (dT · dt ^?1), time to maximum rate under adiabatic situation (TMR_ad), pressure rise rate (dP · dt ^?1), and maximum pressure (P _max), etc. The T ₀ was calculated to be 130?°C using DSC and VSP2. Activation energy (E _a) of TBPO was evaluated to be 136?kJ?mol^?1 by VSP2. In view of the loss prevention, calorimetric applications and model evaluation to integrate thermal hazard development are adequate means for inherently safer design.     

Explosion evaluation and safety storage analyses of cumene hydroperoxide using various calorimeters

Plenty of thermal explosions and runaway reactions of cumene hydroperoxide (CHP) were described from 1981 to 2010 in Taiwan. Therefore, a thermal explosion accident of CHP in oxidation tower in 2010 in Taiwan was investigated because of piping breakage. In general, high concentration of CHP for thermal analysis using the calorimeter is dangerous. Therefore, a simulation method and a kinetic parameter were used to simulate thermal hazard of high concentrations of CHP only by the researcher. This study was applied to evaluate thermal hazard and to analyze storage parameters of 80 and 88 mass% CHP using three calorimeters for the oxidation tower, transportation, and 50-gallon drum. Differential scanning calorimetry (DSC) (a non-isothermal calorimeter), thermal activity monitor III (TAM III) (an isothermal calorimeter), and vent sizing package 2 (VSP2) (an adiabatic calorimeter) were employed to detect the exothermic behavior and runaway reaction model of 80 and 88 mass% CHP. Exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), maximum temperature (T _max), time to maximum rate under isothermal condition (TMR_iso) (as an emergency response time), maximum pressure (P _max), maximum of self-heating rate ((dT/dt)_max), maximum of pressure rise rate ((dP/dt)_max), half-life time (t _1/2), reaction order (n), activation energy (E _a), frequency factor (A), etc., of 80 and 88 mass% CHP were applied to prevent thermal explosion and runaway reaction accident and to calculate the critical temperature (T _c). Experimental results displayed that the n of 80 and 88 mass% CHP was determined to be 0.5 and the E _a of 80 and 88 mass% CHP were evaluated to be 132 and 134 kJ mol^?1, respectively.     

Effects of cumene hydroperoxide on phenol and acetone manufacturing by DSC and VSP2

Cumene hydroperoxide (CHP) being catalyzed by acid is one of the crucial processes for producing phenol and acetone globally. However, it is thermally unstable to the runaway reaction readily. In this study, various concentrations of phenol and acetone were added into CHP for determination of thermal hazards. Differential scanning calorimetry (DSC) tests were used to obtain the parameters of exothermic behaviors under dynamic screening. The parameters included exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), and exothermic peak temperature (T _p). Vent sizing package 2 (VSP2) was employed to receive the maximum pressure (P _max), the maximum temperature (T _max), the self-heating rate (dT/dt), maximum pressure rise rate ((dP/dt)_max), and adiabatic time to maximum rate ((TMR)_ad) under the worst case. Finally, a procedure for predicting thermal hazard data was developed. The results revealed that phenol and acetone sharply caused a exothermic reaction of CHP. As a result, phenol and acetone are important indicators that may cause a thermal hazard in the manufacturing process.     

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Organic peroxides (OPs) have caused many momentous explosions and runaway reactions, resulting from thermal instability, chemical pollutants, and even mechanical shock. In Taiwan, dicumyl peroxide (DCPO), due to its unstable reactive nature, has caused two thermal explosions and runaway reaction incidents in the manufacturing process. To evaluate thermal hazards of DCPO in a batch reactor, we studied thermokinetic parameters, such as heat of decomposition (†H _d), exothermic onset temperature (T ₀), maximum temperature rise ((dT/dt)_max), maximum pressure rise ((dP/dt)_max), self-heating rate (dT/dt), etc., via differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2).     

Evaluation of adiabatic runaway reaction of methyl ethyl ketone peroxide by DSC and VSP2

Methyl ethyl ketone peroxide (MEKPO) is generally applied to manufacturing in the polymerization processes. Due to thermal instability and high exothermic behaviors of MEKPO, if any operation is undertaken recklessly or some environmental effect is produced suddenly during the processes, fires and explosions may inevitably occur. In this study, thermal analysis was evaluated for MEKPO by differential scanning calorimetry (DSC) test. Vent sizing package 2 (VSP2) was used to analyze the thermal hazard of MEKPO under various stirring rates in a batch reactor. Thermokinetic and safety parameters, including exothermic onset temperature (T ₀), maximum temperature (T _max), maximum pressure (P _max), self-heating rate (dT dt ⁻¹), pressure rise rate (dP dt ⁻¹), and so on, were discovered to identify the safe handling situation. The stirring rates of reactor were confirmed to affect runaway and thermal hazard characteristics in the batch reactor. If the stirring rate was out of control, it could soon cause a thermal hazard in the reactor.     

Evaluation of thermal hazard for lauroyl peroxide by VSP2 and TAM III

When above certain temperature limits, lauroyl peroxide is an unstable material. If the thermal source cannot be properly governed during any stage in the preparation, manufacturing process, storage or transport, runaway reactions may inevitably be induced immediately. In this study, the influence of runaway reactions on its basic thermal characteristic was assessed by evaluating thermokinetic parameters, such as activation energy (E _a) and frequency factor (A) by thermal activity monitor III (TAM III). This was achieved under five isothermal conditions of 50, 60, 70, 80, and 90?°C. Vent sizing package 2 (VSP2) was employed to determine the maximum pressure (P _max), maximum temperature (T _max ), maximum self-heating rate ((dT?dt ^?1)_max), maximum pressure rise rate ((dP?dt ^?1)_max), and isothermal time to maximum rate ((TMR)_iso) under the worst case. Results of this study will be provided to relevant plants for adopting best practices in emergency response or accident control.     

Thermal decomposition behavior, kinetics, and thermal hazard evaluation of CMDB propellant containing CL-20 by microcalorimetry

The thermal decomposition behavior of composite modified double-base propellant containing hexanitrohexaazaisowurtzitane (CL-20/CMDB propellant) was studied by microcalorimetry. The kinetic and thermodynamic parameters were obtained from the analysis of the heat flow curves. The effect of different proportion of CL-20 to the thermal decomposition behavior, kinetics, and thermal hazard was investigated at the same time. The critical temperature of thermal explosion (T _b), the self acceleration decomposition temperature (T _SADT), and the adiabatic decomposition temperature rise (??T _ad) were calculated to evaluate the thermal hazard of the CL-20/CMDB propellant. It shows that the CMDB propellant with 38% CL-20 has relative lower values of E and lgA, and with 18% CL-20 has the highest potential hazard.     

Complex thermal evaluation for 2,2′-azobis(isobutyronitrile) by non-isothermal and isothermal kinetic analysis methods

Azo compounds are widely used in dyes, pigments, blowing agents, and initiators. Unfortunately, these compounds contain the bivalent –N–N– composition which might be cleavaged readily even under high ambient temperature. The self-accelerating decomposition might cause a runaway reaction and lead to a fire or explosion when the cooling system fails or other upsets occur. To investigate the thermal stability parameters of 2,2′-azobis(isobutyronitrile) with thermal hazard and mechanism, differential scanning calorimetry and thermal activity monitor III were applied with non-isothermal method and isothermal method to obtain onset temperature (T ₀), maximum temperature (T _max), and heat of decomposition (ΔH _d). Thermal stability parameters play a pivotal role in thermal analysis, leading particularly to complex evaluation of the inherently safer design during preparation, processing, transport, or storage. The results provide sufficient thermokinetic parameters for process safety in terms of proactive loss prevention program.     

Thermal hazard evaluation for methyl ethyl ketone peroxide mixedwith inorganic acids

Methyl ethyl ketone peroxide (MEKPO) possesses complex structures which have caused many incidents involving fires or explosions by mixing with incompatible substances, external fires, and others. In this study, reactivities or incompatibilities of MEKPO with inorganic acids (HCl, HNO₃, H₃PO₄ and H₂SO₄) were assessed by differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2). Parameters obtained by the above-mentioned devices could be readily employed to discuss the runaway reaction, such as onset temperature (T ₀), heat of reaction (ΔH _d), time to maximum rate (TMR), maximum self heat rate (dT/dt)_max, adiabatic temperature rise (ΔT _ad), maximum pressure of decomposition (P _max) and so on. Mixing MEKPO with hydrochloric acid resulted in the lowest T ₀ among inorganic acids. Nitric acid not only lowered the T ₀ but also delivered the highest heat releasing rate or self heat rate (dT/dt), which was concluded to be the worst case in terms of contamination hazards during storage or transportation of MEKPO.     

Evaluating the Thermal Hazard of Double-Base Propellant SQ-2 by Using Microcalorimetry Method

The thermal decomposition behavior of double‐base rocket propellant SQ‐2 was studied by a Calvet microcalorimeter at four different heating rates. The kinetic and thermodynamic parameters were obtained from the analysis of the heat flow curves. The critical temperature of thermal explosion (T_b), the self acceleration decomposition temperature (T_SADT), the adiabatic decomposition temperature rise (ΔT_ad), the time‐to‐explosion of adiabatic system (t), critical temperature of hot‐spot initiation (T_cr), critical thermal explosion ambient temperature (T_acr), safety degree (SD) and thermal explosive probability (P_TE) were presented to evaluate the thermal hazard of SQ‐2.     

Thermal runaway hazards of <Emphasis Type="Italic">tert</Emphasis>-butyl hydroperoxide by calorimetric studies

Thermal runaway reactions associated with exothermic behaviors of tert-butyl hydroperoxide (TBHP) solutions and TBHP reacting with alkaline contaminants were studied. A differential scanning calorimetry (DSC) was used to characterize these inherent behaviors of TBHP solutions with KOH, NaOH, LiOH and NH₄OH. The exothermic peak in thermal curves of TBHP solutions with different alkali were detected by DSC thermal analysis. By thermal analysis, we compared various heats of decomposition of TBHP solutions with alkaline impurities, and determined the incompatible hazards of various TBHP solutions with alkaline contaminants. Comparing with TBHP in various diluents, the adiabatic runaway reaction via vent sizing package 2 (VSP2) indicated that aqueous TBHP intrinsically possesses the phenomena of thermal explosion with dramatic self-reactive rate and pressure rise under adiabatic conditions. Many commercial organic peroxides may have different hazard behaviors. Therefore, using thermal method to classify the hazards is an important subject.     

Evaluation of thermal hazard for commercial 14500 lithium-ion batteries

Commercial lithium-ion batteries ranged from different sizes, shapes, capacities, electrolytes, anode and cathode materials, etc. have recently caused many incidents under abusive or normal operating conditions worldwide. Inherently safer designs with active or passive protections have became the captious issues that need more attentions paid to. In this study, the worst scenarios on thermal runaway of four commercial batteries were conducted and compared. A customized-made closed testing instrument was utilized to measure and track thermal behaviors of four brands of cylindrical lithium-ion batteries under maximum open circuit voltage condition. Characteristics on thermal hazards of lithium-ion batteries such as onset temperature, maximum temperature, maximum self-heat rate, maximum pressures, battery mass loss, etc. were measured and evaluated. Results point out that one brand of cells reached the maximum temperature and maximum self-heat rate of 590.9 K and 1,130.4 K min^?1, respectively. In conclusion, in case of thermal runaway all the lithium-ion batteries will rupture the cell and catch fire automatically owing to the maximum temperatures over the auto-ignition temperature of electrolytes and the maximum pressure higher than four times of maximum allowable working pressure, respectively. In addition, Lithium-ion battery with cathode material of LiFePO₄ was verified to be more stable than the lithium-ion battery with cathode material of LiMn₂O₄ or LiCoO₂.     

Thermal hazard analyses of organic peroxides and inorganic peroxides by calorimetric approaches

Organic peroxides (OPs) and inorganic peroxides (IPs) are usually employed as an initiator for polymerization, a source of free radicals, a hardener, and a linking agent in low density polyethylene (LDPE), polyvinyl chloride (PVC), controlled-rheology polypropylene (CR-PP), and styrene industries. Worldwide, due to their unstably reactive natures, OPs and IPs have caused many serious thermal explosions and runaway reaction incidents. This study was conducted to elucidate its essentially hazardous characteristics. To analyze the runaway behavior of OPs and IPs in the traditional process, thermokinetic parameters including heat of decomposition (??H _d ), exothermic onset temperature (T ₀), self-accelerating decomposition temperature (SADT), time to maximum rate (TMR), critical temperature (T _c ), etc., were measured by calorimetric approaches involving differential scanning calorimetry (DSC), vent sizing package 2 (VSP2), and calculation method. Safety and health handling information of hazardous materials and toxic substances is noted in material safety data sheets (MSDS) and was applied to analyze in process safety management (PSM) in the chemical industries, but MSDS are not providing important handling indicators concerning the SADT, TMR, T _c , etc. In view of loss prevention, more useful indicators must be provided in the sheets or guide book.     

Thermal decomposition of hydrogen peroxide in the presence of sulfuric acid

Hydrogen peroxide (H₂O₂) is popularly employed as a reaction reagent in cleaning processes for the chemical industry and semiconductor plants. By using differential scanning calorimetry (DSC) and vent sizing package 2 (VSP2), this study focused on the thermal decomposition reaction of H₂O₂ mixed with sulfuric acid (H₂SO₄) with low (0.1, 0.5 and 1.0 N), and high concentrations of 96 mass%, respectively. Thermokinetic data, such as exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), pressure rise rate (dP/dt), and self-heating rate (dT/dt), were obtained and assessed by the DSC and VSP2 experiments. From the thermal decomposition reaction on various concentrations of H₂SO₄, the experimental data of T ₀, ΔH, dP/dt, and dT/dt were obtained. Comparisons of the reactivity for H₂O₂ and H₂O₂ mixed with H₂SO₄ (lower and higher concentrations) were evaluated to corroborate the decomposition reaction in these systems.     

Thermal explosion and runaway reaction simulation of lauroyl peroxide by DSC tests

Lauroyl peroxide (LPO) is a typical organic peroxide that has caused many thermal runaway reactions and explosions. Differential scanning calorimetry (DSC) was employed to determine the fundamental thermokinetic parameters that involved exothermic onset temperature (T₀), heat of decomposition (ΔH_d), and other safety parameters for loss prevention of runaway reactions and thermal explosions. Frequency factor (A) and activation energy (E_a) were calculated by Kissinger model, Ozawa equation, and thermal safety software (TSS) series via DSC experimental data. Liquid thermal explosion (LTE) by TSS was employed to simulate the thermal explosion development for various types of storage tank. In view of loss prevention, calorimetric application and model analysis to integrate thermal hazard development were necessary and useful for inherently safer design.     

Study on thermal hazards for isoprene monomer (IPM) mixed with aluminum oxide

Isoprene monomer (IPM) is a colorless, volatile liquid obtained from petroleum or coal tar that occurs naturally in many process plants. It is used chiefly to make synthetic rubber. Our study used calorimetric approaches to conduct thermal analysis and hazard assessment of aluminum oxide (Al₂O₃) and IPM relevant studies. Differential scanning calorimetry, thermal activity monitor III, thermogravimetry, and vent sizing package 2 were used to discuss thermal instability reaction of Al₂O₃, which adsorbed IPM, and find every possible reason for cases of fire to prevent any future recurrence of the package store and transport related hazards. By means of calorimetric analysis technology, we can observe thermal decomposition or mass loss for different adsorbed concentrations of IPM and Al₂O₃ to discuss the related thermal stability parameters, such as exothermic onset temperature (T ₀), heat of decomposition (ΔH _d), self-accelerating exothermic rate (dT dt ^?1), pressure rise rate, and maximum reaction temperature (T _max). Then, we can understand the potential hazard factors that contribute to disasters related to processing, transport, and storage of security controls and reaction process design.     

Thermal explosion simulation and incompatible reaction of dicumyl peroxide by calorimetric technique

Dicumyl peroxide (DCPO) is usually employed as an initiator for polymerization, a source of free radicals, a hardener, and a linking agent. In Asia, due to its unstable reactive nature, DCPO has caused many thermal explosions and runaway reaction incidents in the manufacturing process. This study was conducted to elucidate its essentially thermal hazard characteristics. In order to analyze the runaway behavior of DCPO in a batch reactor, thermokinetic parameters, such as heat of decomposition (ΔH _d) and exothermic onset temperature (T ₀), were measured via differential scanning calorimetry (DSC). Thermal runaway phenomena were then thoroughly investigated by DSC. The thermokinetics of DCPO mixed with acids or bases were determined by DSC, and the experimental data were compared with kinetics-based curve fitting of thermal safety software (TSS). Solid thermal explosion (STE) and liquid thermal explosion (LTE) simulations of TSS were applied to determine the fundamental thermal explosion behavior in large tanks or drums. Results from curve fitting indicated that all of the acids or bases could induce exothermic reactions at even an earlier stage of the experiments. In order to diminish the extent of hazard, hazard information must be provided to the manufacturing process. Thermal hazard of DCPO mixed with nitric acid (HNO₃) was more dangerous than with other acids including sulfuric acid (H₂SO₄), phosphoric acid (H₃PO₄), and hydrochloric acid (HCl). By DSC, T ₀, heat of decomposition (ΔH _d), and activation energy (E _a) of DCPO mixed with HNO₃ were calculated to be 70 °C, 911 J g⁻¹, and 33 kJ mol⁻¹, respectively.     

Isothermal versus non-isothermal calorimetric technique to evaluate thermokinetic parameters and thermal hazard of tert-butyl peroxy-2-ethyl hexanoate

Liquid organic peroxides have been broadly employed in the process industries such as tert-butyl peroxy-2-ethyl hexanoate (TBPO). This study investigated the thermokinetic parameters of TBPO, a typical liquid organic peroxide, by isothermal kinetic algorithms and non-isothermal kinetic algorithms with thermal activity monitor III, and differential scanning calorimetry, respectively. An attempt has been made to determine the thermokinetic parameters by simulation software, such as exothermic onset temperature (T ₀), maximum temperature (T _max), decomposition (?H _d), activation energy (E _a), self-accelerating decomposition temperature, and isothermal time to maximum rate (TMR_iso). A liquid thermal explosion model was established for a reactor containing liquid organic peroxide of interest. From experimental results, liquid organic peroxides?? optimal conditions for avoiding a violent runaway reaction of storage and transportation were created.