Mining operators across Australia are rapidly switching to wind, solar and battery energy storage systems (BESS) to reduce operational costs, enhance energy security and lower emissions.
Many operators have made significant progress toward sustainability targets, yet reducing reliance on diesel generators and vehicles remains a crucial challenge. Australian government data shows the mining sector consumes roughly one-tenth of the country’s total energy use, with 41 per cent coming from diesel.
Wind and solar offer clear cost, operational and sustainability benefits over diesel generators, yet this transition introduces energy generation and storage complexities. That’s why many operators are switching to BESS systems powered by lithium-ion batteries, which safeguard energy availability and help mining operators meet emissions standards.
Mining companies typically roll out lithium-ion BESS alongside existing diesel generators as part of a phased approach to improve redundancy and incorporate more renewables into their energy mix. But while these systems offer game-changing sustainability benefits, they also present new risks that mining operators need to understand and address for safe, reliable deployment.
Understanding the risks
Lithium-ion batteries are vulnerable to severe fires and explosions stemming from a phenomenon known as thermal runaway – a chain reaction that is exceptionally difficult to contain.
Thermal runaway is a phenomenon where a battery cell produces more heat than it can expel, damaging the flammable electrolytes within batteries, which can then ignite or explode, continuously burning until all flammable material is consumed.
While the mining industry is still early in its BESS journey, the rapid escalation of installations – and the hot and dry Australian climates where many sites are located – raise the risk of battery damage and thermal runaway.
As multiple battery cells are typically installed in close proximity, a single fire can spread quickly, posing a serious safety and operational hazard. Incidents are common: FM research shows at least 44 lithium-ion BESS fire-related incidents were publicly reported between 2017 and 2022, with many incidents making headlines across industries.
One of the highest-profile incidents came when a coolant leak triggered thermal runaway during the construction of Tesla’s ‘Big Battery’ project in Victoria. The incident destroyed two Tesla Megapack units, triggered a warning for toxic smoke and took four days before firefighters deemed the site under control.
There have been also multiple BESS incidents at data centres around the world, which typically house large-scale battery systems in isolated rooms for backup power. These events damaged expensive infrastructure and caused major disruptions to key digital services for consumers and businesses for days.
Prevention is better than cure
Within the mining context, a large-scale ESS failure could threaten worker safety, damage expensive equipment and lead to costly operational disruptions. As operators continue to adopt lithium-ion ESS technology, it’s essential to understand the potential for thermal runaway and to plan for its containment.
Addressing the intrinsic risks associated with lithium-ion ESS requires expert support and a nuanced strategy tailored to mining operations.
FM research into lithium-ion battery safety sheds light on how dangerous thermal runaway can be for organisations with large BESS infrastructure. It found that prevention is complex and requires a comprehensive risk and mitigation strategy that extends beyond basic fire measures.
Sprinkler systems, for example, are critical to help control a blaze, but they aren’t enough to fully mitigate a thermal runaway event. Operators should evaluate a range of factors, including:
- Strategic placement – Positioning ESS units away from critical equipment, high-traffic zones and infrastructure vulnerable to fire damage
- Non-combustible enclosures – Constructing battery housing with materials that inhibit fire spread and mitigate the impact of potential explosions
- Separation and ventilation – Spacing battery racks sufficiently apart to prevent cascading thermal runaway and installing robust ventilation and temperature controls
- Emergency response and redundancy – Developing detailed emergency evacuation, fire suppression and redundancy plans, acknowledging limited firefighting resources at remote locations
- Ongoing maintenance and upgrades – Implementing routine inspections, early fault detection and regular system upgrades to identify safer battery technologies as they emerge
Even with thorough preventive measures, thermal runaway events may still occur. Regular consultation with engineering and loss-prevention experts continually minimise risks while maximising the potential of lithium-ion ESS investments.
Forging a new energy future
When managed effectively, lithium-ion ESS unlock considerable benefits for mining operators, offering quieter energy generation, reduced diesel dependency, lower emissions and significant operational cost savings. But managing the inherent risks of these systems requires mitigation strategies backed by robust scientific research and expert engineering advice.
Mining operators need to prioritise ongoing maintenance, strategic installation practices, regular safety reviews and continual investment in the latest battery technologies. Adopting a proactive approach to these challenges facilitates faster deployment, allowing operators to reduce costs and accelerate progress toward net-zero targets.