Lithium mining's new problem: Fire risks and worker safety in battery-era mining

Lithium is among the most valuable elements of clean energy, from electric vehicles (EVs) to grid-scale battery storage. However, there are significant dangers associated with mining and processing it, creating an urgency for enhanced safety practices within the industry.

The white gold powering the future

Lithium demand is soaring due to the EV revolution and the rising need for renewable energy storage. Iola Hughes, Head of Research at Benchmark Mineral Intelligence, expected nearly 44% growth in the battery market in 2025 — driven by lithium iron phosphate (LFP) — with energy storage accounting for roughly one-quarter of the global demand.

Meanwhile, EV manufacturers Tesla and BYD accounted for 68% of the LFP battery market worldwide in 2022. The remaining 32% of production came from GAC, MG and Geely.

LFP batteries are now more cost-effective to manufacture due to the use of abundant iron instead of expensive cobalt. Their chemistry also provides optimal safety and a longer lifespan.

Why lithium mining is a fire hazard

Even with a positive shift toward safer battery chemistry, the risks remain embedded in lithium processing. Fire hazards are one of the many dangers that pose a threat.

The science of lithium fires

Lithium is highly volatile — as the lightest metal, it is extremely flammable and reactive, particularly when exposed to water and air. Its reactivity is the main reason why fires occur in lithium-ion batteries, also known as thermal runaway.

Damage, short circuiting and overheating can trigger violent chain reactions in battery cells. The cell may release toxic, flammable gases, resulting in an explosive fire that is difficult to extinguish. These properties raise risks for workers during mining, processing, and transport.

From extraction to processing

During extraction itself, there is a lower fire risk associated with raw lithium ore. Workers should be more cautious about ruptured hydraulic lines or fuel leaks when using diesel-powered equipment.

Fire risks escalate during processing, though. For example, converting lithium salts into pure metal involves melting them at over 800° Fahrenheit, which emits harmful toxins. The situation becomes even more precarious when flammable liquid electrolytes are added during battery cell assembly and testing.

Furthermore, outdated equipment and electrical infrastructure pose a bigger fire threat, making upgrading critical components, such as switchgear, a crucial safety strategy.

Worker safety in the lithium age

Worker safety is of the utmost importance in the lithium age, particularly given the heightened risk of respiratory conditions associated with extraction.

Health hazards beyond fire

Studies show that lithium is toxic to the kidneys and thyroid gland and may also impact brain function and mental health.

Mining for lithium also exposes workers to fine particles and crystalline silica, which may cause irreversible lung damage. Some develop silicosis and chronic obstructive pulmonary disease as dust accumulates.

The critical need for specialised training and PPE

Standard safety procedures are insufficient to address lithium hazards, from particulate buildup to thermal runaway and reactive chemical exposure.

Safety training cannot be optional, and personnel must learn to suppress lithium fires and chemical spills. Likewise, advanced personal protective equipment should include chemical-resistant suits, respirators and specialised gloves in defence against modern mining risks.

Creating a safer mining future

Demand for lithium will only rise. Therefore, the mining industry must understand and transform its approach to safety, whether extracting ore or assembling lithium batteries.

Author bio

Jane Marsh is a seasoned environmental journalist and the Editor-in-Chief of Environment.co, specialising in in-depth coverage of environmental trends, sustainability, and the evolving energy landscape. With her work featured on leading platforms like Renewable Energy Magazine, Manufacturing.net, and Nation of Change, Jane brings a keen perspective on the intersection of energy innovation and industry practice.

Read the article online at: https://www.globalminingreview.com/mining/14012026/lithium-minings-new-problem-fire-risks-and-worker-safety-in-battery-era-mining/