Emergency landings due to battery fires on the rise globally

Emergency landings due to battery fires have become an alarming trend in air travel. In October, a British Airways flight was forced to make an emergency landing after a passenger's device caught fire, causing significant concern among travelers.

The Federal Aviation Administration (FAA) has reported a staggering 28 battery fire events on passenger and cargo planes in the first quarter of this year alone. If this trend continues, it is likely to surpass last year's record of 97 events, which itself was an increase from 89 incidents in 2024. This surge in battery-related fires poses a significant threat to air travel safety.

The FAA has been tracking these incidents closely, and the numbers are alarming. With more devices relying on batteries than ever before, it is essential for passengers to be aware of the risks involved and take necessary precautions. The enclosed space of an airplane makes fires particularly hazardous, making it crucial for travelers to pack their devices safely.

Any battery can potentially start a fire if not stored correctly, but lithium metal (non-rechargeable) and lithium-ion (rechargeable) batteries are considered the biggest threats. As air travel becomes increasingly dependent on portable electronics, understanding how to pack these devices safely is essential for preventing such incidents from occurring in the future.

Lithium batteries have become increasingly popular over recent years due to their compact size and long-lasting power.

However, this surge in demand has also led to an increased risk of thermal runaway, a self-sustaining chemical reaction that produces extreme heat, toxic smoke, ultrafine particles, and flames within seconds.

This can happen unexpectedly due to various factors such as damage to the battery, overheating, overcharging, exposure to water, or manufacturing defects.

The resulting lithium battery fires are notoriously difficult for cabin crews to extinguish using traditional methods.

Lithium batteries are commonly found in a range of portable electronics, including cell phones, laptops, vapes, and power banks.

These devices have been linked to several aircraft incidents, with notable cases involving a laptop battery fire on an American Airlines plane in 2024 that injured three passengers.

A similar emergency occurred on a Virgin Australia flight in 2025 when a power bank caught fire.

In addition to power banks, other devices that contain lithium batteries pose a risk during air travel. These include wireless earbuds and noise-canceling headphones, which are commonly used by passengers. Some electronic devices, such as cameras and drones, also contain lithium batteries.

To determine whether your device has a lithium battery, check the label or manual for specific information. For coin-cell batteries, the label will typically start with "CR" if lithium is involved. This is an essential step in understanding the regulations surrounding lithium batteries during air travel.

The size of the lithium battery and its installation in a device also play a crucial role in determining the regulations that apply. Non-rechargeable batteries are limited to 2 grams of lithium per battery, while rechargeable batteries have a rating limit of 100 watt hours. This distinction is critical for travelers who want to pack their devices safely.

The rules governing lithium batteries can be confusing, but being aware of these limitations is essential for avoiding any issues during air travel. By understanding the regulations and taking necessary precautions, passengers can ensure a safe and smooth journey.

When it comes to packing larger batteries for air travel, approval from the airline is required.

Spare or uninstalled lithium batteries, including power banks and cell phone charging cases, are prohibited in checked baggage by the Transportation Security Administration (TSA). These must be carried in a passenger's carry-on luggage instead.

If a gate-check is necessary, passengers must remove these types of batteries from their bags and keep them with them throughout the flight. This ensures that they remain within easy access at all times.

Additionally, lithium batteries contained within devices can usually be packed in checked baggage as long as the device is fully powered off to prevent accidental activation.

When packing batteries for travel, it's essential to know which types are allowed in checked and carry-on bags. Dry batteries such as AAs, button cells, and 9-volts can be safely packed in both categories.

To keep batteries secure during transit, consider storing them in their original packaging or a protective case. This can include the battery pocket of a camera bag or even a plastic baggy. These precautions help prevent accidental activation and potential damage to surrounding items.

It's worth noting that rechargeable batteries should not be packed with their charging units. Instead, store them separately to avoid any potential issues during travel. This simple step can make a significant difference in maintaining the safety of your luggage.

During a flight, being aware of lithium battery safety is crucial. If you notice a device overheating or smoking, alert the crew immediately. Additionally, if you drop a lithium battery-containing device between seats, notify a crew member promptly to ensure a swift response in case of an emergency.

Travelers who fail to adhere to battery-packing guidelines may face significant fines, but more critically, they also put others at risk on their flight.

To avoid such consequences and ensure a trouble-free journey, it is essential to follow the recommended packing practices for lithium batteries and devices as outlined earlier in this article. Additionally, being mindful of your surroundings during flights can help prevent accidents, such as dropping a device containing lithium batteries between seats.

By taking these precautions, travelers can minimize risks associated with battery-related incidents on planes, ultimately contributing to a safer travel experience for everyone involved.