Lithium Battery Fires Pose Growing Threat to Maritime Export of China’s “New Trio”
In recent years, China’s export landscape has been reshaped by a new wave of high-tech, green-energy products—electric vehicles (EVs), lithium batteries, and photovoltaic (PV) panels—collectively dubbed the “New Trio.” These goods have not only become symbols of China’s industrial transformation but also key drivers of its new quality productive forces. In 2023 alone, the trio’s combined export value surpassed RMB 1 trillion for the first time, growing by nearly 30% year-on-year. By the first quarter of 2024, exports of electric passenger vehicles, solar cells, and lithium-ion batteries continued their upward trajectory, posting year-over-year increases of 28.5%, 24.7%, and 5.9%, respectively.
Maritime shipping remains the dominant channel for these exports, favored for its capacity, cost efficiency, and global reach. Yet as volumes surge, so do the risks—particularly those associated with lithium batteries and battery-powered vehicles. Incidents such as the catastrophic fire aboard the Felicity Ace in early 2022, which resulted in the total loss of a vessel carrying nearly 4,000 vehicles—including numerous EVs—have spotlighted the acute safety challenges facing the industry. Investigations pointed to thermal runaway in lithium-ion batteries as the likely ignition source, underscoring a systemic vulnerability that regulators, shippers, and manufacturers are still struggling to contain.
The maritime sector’s traditional fire suppression systems—designed for conventional cargo and internal combustion engine vehicles—are ill-equipped to handle the unique combustion dynamics of lithium battery fires. Once ignited, these fires burn at temperatures exceeding 1,000°C, release toxic gases like hydrogen fluoride, and can reignite multiple times even after apparent extinguishment. Water remains the most effective suppressant, but its massive volume requirement poses a secondary threat: compromising a ship’s stability if drainage systems are overwhelmed.
Against this backdrop, maritime authorities in China, particularly the Xiamen Maritime Safety Administration (MSA), are racing to adapt regulatory frameworks, enhance emergency response protocols, and align domestic standards with evolving international norms. A recent study published in China Maritime Safety by Chen Yanyan and Feng Zengfang of the Xiamen MSA delves into the multifaceted risks and regulatory gaps surrounding the maritime export of the “New Trio,” offering a roadmap for safer, more resilient logistics chains.
The Hidden Dangers Beneath the Green Facade
While photovoltaic panels are generally classified as non-hazardous cargo, both EVs and lithium batteries fall under Class 9 of the International Maritime Dangerous Goods (IMDG) Code, reflecting their potential to pose risks during transport. The IMDG Code currently lists seven distinct UN entries relevant to these products, ranging from standalone lithium-ion cells (UN 3480) to battery-powered vehicles (UN 3171) and even large-scale battery systems installed in shipping containers (UN 3536).
The core hazard lies in the electrochemical instability of lithium-based chemistries. Thermal runaway—a self-sustaining chain reaction triggered by internal short circuits, mechanical damage, or exposure to high temperatures—can escalate from initial smoke to full-blown fire in under six seconds. In dense cargo configurations, such as vehicle decks on roll-on/roll-off (ro-ro) ships or tightly packed containers, a single battery failure can cascade into a fleet-wide conflagration.
Compounding the risk are external stressors inherent to ocean transport: violent motion during storms, container stack collapses, inadequate lashing, and prolonged exposure to tropical heat. Poorly secured EVs can shift during rough seas, damaging battery enclosures and initiating thermal events. Similarly, substandard packaging or improper state-of-charge management (batteries shipped above 30% capacity are at higher risk) further elevates danger.
Perhaps most troubling is the rise of non-standard or second-hand products entering the export stream. As China’s domestic EV and battery markets mature, a growing volume of used EVs, “zero-kilometer” reconditioned vehicles, and repurposed or recycled battery packs are being shipped overseas—often without clear regulatory classification or safety certification. Some shippers, facing pressure to move goods quickly and cheaply, resort to misdeclaration or concealment, bypassing mandatory dangerous goods protocols altogether.
This trend is exacerbated by the explosive growth of cross-border e-commerce, which funnels millions of small parcels containing lithium-powered devices—power banks, e-scooters, robotic lawnmowers—into maritime logistics networks. These items, though individually low-risk, collectively create a complex compliance burden. Current IMDG requirements for packaging, labeling, segregation, and documentation are difficult to enforce at scale, especially on short-sea routes like those serving Taiwan, Hong Kong, and Macao under the “Mini Three Links” framework.
Regulatory Gaps and Enforcement Challenges
Despite commendable efforts by Chinese maritime authorities—including the establishment of fast-track inspection lanes, joint verification mechanisms with customs, and the drafting of a national technical standard titled Safety Requirements for Ships Carrying Lithium Batteries—significant regulatory gaps persist.
One major issue is the lag between technological innovation and international rulemaking. The IMDG Code, updated biennially, struggles to keep pace with the rapid evolution of battery chemistries. Sodium-ion batteries, solid-state designs, and novel cathode formulations are already entering commercial production, yet their transport classifications remain ambiguous or absent. Even when new entries are proposed, the multi-year adoption cycle at the International Maritime Organization (IMO) means ships may be carrying unregulated or misclassified cargo for years.
Moreover, inconsistent interpretation of existing rules across jurisdictions creates operational friction. A shipment deemed compliant in Shanghai might be detained in Rotterdam or Los Angeles due to differing enforcement philosophies or local amendments. This unpredictability increases costs, delays, and legal exposure for exporters and carriers alike.
Domestically, many frontline maritime inspectors lack specialized training in battery technology or EV logistics. While the Xiamen MSA has launched a dedicated “Doctoral Studio” led by Dr. Feng Zengfang—a chemist by training and a recognized expert in hazardous materials—to bridge this knowledge gap, nationwide capacity remains uneven. Without a standardized, science-based inspection protocol, enforcement risks becoming either overly permissive or arbitrarily stringent.
Charting a Safer Course Forward
In their study, Chen and Feng propose a four-pronged strategy to strengthen maritime safety without stifling trade:
First, intensify applied research into the transport safety of emerging product categories—especially second-life batteries and used EVs. Understanding how aging, prior damage, or non-standard modifications affect thermal stability is critical to setting realistic safety thresholds.
Second, expand the scope of vessel suitability assessments. While ro-ro ships are the traditional choice for vehicle exports, capacity constraints have led to the use of bulk carriers, container ships, and even specialized vessels like pulp carriers retrofitted to carry EVs. Each vessel type presents unique fire risks and requires tailored stowage, ventilation, and monitoring protocols. Research into “one container, multiple vehicles” configurations and seamless intermodal transport (“one-document, one-container” systems) could also improve efficiency while maintaining safety.
Third, accelerate the development and deployment of next-generation fire detection and suppression technologies. Traditional smoke detectors often fail to provide early warning for lithium fires, which may smolder internally before erupting. Infrared thermal imaging, gas sensors tuned to battery off-gassing signatures, and AI-powered video analytics offer promising avenues for earlier intervention. On the suppression side, while no silver-bullet extinguishing agent exists yet, hybrid systems combining water mist, inert gases, and thermal barriers show potential in containment scenarios.
Fourth, enhance pre-shipment engagement and regulatory harmonization. Maritime authorities should proactively consult with manufacturers, logistics providers, and standards bodies to clarify compliance expectations. For short-sea e-commerce flows, simplified but robust safety frameworks—such as standardized small-battery declarations and pre-approved packaging templates—could balance risk mitigation with operational practicality. Internationally, China must leverage its leadership in battery production to shape upcoming IMO discussions, ensuring that new rules reflect real-world technical realities rather than theoretical worst cases.
A Strategic Imperative in a Fracturing Global Order
The stakes extend beyond safety. As Western economies pivot toward “de-risking” and erect carbon-related trade barriers—such as the EU’s Carbon Border Adjustment Mechanism—the secure, reliable export of the “New Trio” has become a matter of national economic strategy. Any major maritime incident involving Chinese EVs or batteries could fuel protectionist narratives, trigger import restrictions, or erode consumer confidence abroad.
Conversely, demonstrating world-class logistics safety could reinforce China’s reputation as a responsible supplier of green technology. By investing in science-based regulation, transparent enforcement, and international collaboration, Chinese maritime authorities can turn a vulnerability into a competitive advantage.
The path forward demands coordination across disciplines: chemistry, naval architecture, fire science, regulatory policy, and supply chain management. It also requires humility—recognizing that today’s solutions may be obsolete tomorrow as battery technologies evolve. But with proactive leadership from institutions like the Xiamen MSA and experts like Feng Zengfang and Chen Yanyan, China is well-positioned to navigate these turbulent waters.
As global demand for clean energy solutions continues to rise, the safe maritime transport of the “New Trio” will remain a critical enabler of the energy transition—and a litmus test for China’s ability to export not just products, but trust.
By Chen Yanyan and Feng Zengfang, Xiamen Maritime Safety Administration, Xiamen, Fujian 361000, China. Published in China Maritime Safety, 2024, Vol. 21, No. 8, pp. 25–28. DOI: 10.3969/j.issn.1673-2278.2024.08.006.