In this customer-written case study, Bradley Peirce from University of Warwick (WMG) shares how they use Gasmet’s FTIR technology to investigate lithium-ion batteries thermal runaway. For WMG, understanding which gases are released during battery failure provides the evidence needed to assess risks and develop effective mitigation strategies.

Thermal runaway events in lithium-ion batteries can generate complex gas mixtures that are flammable, explosive, and highly toxic. Accurately characterising these gases is therefore critical for understanding the hazards associated with battery failures and for improving safety assessments, predictive models, and mitigation strategies.

Battery thermal runaway is a highly dynamic event. Gas composition can change rapidly throughout the failure process, making reliable measurement difficult. Variations in venting behaviour, gas density, and ejected material can all influence the quality of collected data, creating challenges when attempting to quantify the real risks posed by individual events.

Tracking thermal runaway gases with the Gasmet DX4000

To address this challenge, we deployed the Gasmet DX4000 FTIR gas analyser (predecessor to GT6000 Mobilis) across several battery safety research projects. Using the advanced library, we have been able to monitor the evolution of gas composition throughout thermal runaway events and identify a wide range of gaseous species generated during failure.

One of the key advantages of FTIR analysis using the DX4000 is the ability to measure multiple gas species in real time at a fast response rate. This provides a far more comprehensive understanding of thermal runaway behaviour.

 

Investigating battery failure propagation in the SafeBatt project

A specific case where the Gasmet analyser has been used at WMG was in the Faraday Institution-funded SafeBatt project. This part of the project aims to inform the development of effective failure mitigation strategies by using instrumentation and high-speed diagnostic techniques to study dynamic failure and the effects of failure and propagation.

In this specific set of tests, we are analysing the propagation characteristics of 90 Ah pouch cells commonly used in the automotive sector. The following results show elevated levels of combustion products and of products specific to battery thermal runaway reactions such as EMC, DC, and dichloromethane which are constituents of the electrolyte mixture decomposition.

Building confidence in measurement data through technical collaboration with Gasmet

The support provided by Gasmet has been critical to this aspect of the project. Claire Johnston, alongside Gasmet’s technical team, worked closely with us during commissioning and analysis of results, helping resolve instrumentation and measurement challenges.

Through this collaboration with Gasmet, we have reached a level where we can be confident in both our data quality and interpretation of results.

Expanding battery safety research and continuous gas monitoring

The combination of the Gasmet DX4000 and advanced battery safety testing methodologies is enabling deeper insight into thermal runaway behaviour. As understanding of gas evolution continues to improve, these measurements will play an increasingly important role in risk assessment, safety validation, and the development of safer battery systems.

By March 2027 we will have completed commissioning of a new battery safety laboratory which will be capable of testing larger prismatic cells and small modules.

This includes two new Gasmet CEMS II units to perform two different tasks.

• The first unit will operate as a Continuous Emissions Monitoring System which will measure the gases that our laboratory is emitting from the stack of our gas scrubbing system. This will keep us compliant with regulations and ensure that we are operating responsibly and keeping people in the area of the facility completely safe.
• The second unit will measure gases within our test chambers on a routine basis so that we can collect data from every thermal runaway test with minimum effort. This system includes integrated hydrogen and oxygen sensors which allow us to calculate explosivity of vented gases.

Taken together, this equipment will represent a step forward in the UK’s capability for research into lithium-ion battery safety.

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GT6000 Mobilis – Gasmet solution for battery safety testing The GT6000 Mobilis heated gas analyzer provides an ideal solution to be used in different battery safety-related applications. In addition to thermal runaway research, the analyzer is suited for measurements in off-gassing, battery fire research, battery recycling (crushing and solvent recovery) and gas detection in logistics and warehousing. Read more about GT6000 Mobilis here

CEMS II e – Gasmet solution for continuous gas monitoring The CEMS II e continuous emissions monitoring system provides a versatile solution for monitoring battery off-gases in ventilation systems. By continuously measuring up to 50 gases simultaneously, including hydrogen fluoride (HF), the system provides comprehensive gas composition data to support early detection and measures to prevent hazardous gas build-up. Read more about CEMS II e here