Why airlines are warning over lithium-ion batteries

In June 2025, a technology journalist named Ben Wodecki witnessed something unusual during a flight into Las Vegas - panicked flight crew rushing to the rear of the plane. Smoke and distressed passengers emerged, revealing that a passenger had been using a battery pack, which had overheated and burst into flames, setting a seat alight.

The plane made an emergency landing at Harry Reid International Airport, where fire crews were on standby. This incident highlights the growing concerns over the dangers of lithium-ion batteries on flights.

Lithium-ion batteries, used in devices like power banks and vapes, have become a significant fire risk on planes. Jonathan Nicholson, from the UK's Civil Aviation Authority, notes that for the airline industry, these batteries have been a top risk for a few years now. A recent US study found that there are roughly two lithium-ion battery-related incidents per week worldwide.

These incidents can range from passengers inadvertently leaving devices in checked baggage to fires starting in airport baggage halls or during flights. In January 2025, an Air Busan plane was destroyed on the tarmac in South Korea when a power bank battery pack left in an overhead luggage compartment caused the incident. This prompted the International Air Transport Association (IATA) to launch a global campaign to encourage safe practices when traveling with lithium batteries.

The increase in lithium-ion-related incidents is attributed to more people, more flights, and more devices. The US Federal Aviation Administration reported 51 verified incidents for the year to July 15, 2025. While the lithium itself does not burn, it can heat up extremely fast, reaching temperatures of 700 to 1000 degrees Celsius. The dangers of these batteries became public knowledge following a series of phone-related fires about a decade ago, which were caused by flawed designs.

South Korea is a leader in addressing these issues, but the proliferation of cheaply produced battery packs from East Asia and the lack of stringent quality controls contribute to the problem. Passengers often exacerbate the issue by using unsuitable cables and not properly caring for their devices. As a result, airlines are forced to issue frequent warnings and use tried-and-tested methods to quickly address incidents when they occur.

The CAA's Nicholson emphasizes the importance of keeping devices in the cabin and not in overhead compartments or the hold. He advises that the most effective method is to simply douse the device in water and cool it down. However, some airlines use specialized containment devices. The technology and personal device industries are heavily invested in lithium-ion technology, making it challenging to find viable alternatives.

Sodium-ion batteries, for example, are currently double the cost of lithium devices for consumers. Kubiak suggests that more focus should be placed on safeguarding the existing technology rather than seeking a complete ban on battery banks on planes.