In-situ Gas Analysis System for Lithium Battery Thermal Runaway，thermal runaway gas monitoring system

The In-situ Gas Analysis System for Lithium Battery Thermal Runaway is an advanced testing platform designed to trigger and monitor battery thermal runaway events within a controlled environment. Using a battery cell pressure vessel as the primary trigger carrier, the system integrates real-time signal detection, gas sampling, and online gas composition analysis. It enables flexible sample loading, thermal runaway initiation, and precise monitoring of generated gases, while providing reliable measurement data for gas volume, gas evolution rate, and explosion pressure. This system supports research, production, and safety assessment of lithium batteries, contributing to effective hazard evaluation across multiple applications.

Application

Battery Research and Development

Provides controlled thermal runaway testing for lithium battery cells, enabling analysis of gas composition, pressure evolution, and reaction kinetics.

Battery Manufacturing and Quality Control

Evaluates battery safety and consistency under abuse conditions, supporting process improvements and production safety verification.

Battery Safety Certification

Offers standardized testing aligned with UL 9540A for thermal runaway fire propagation, supporting regulatory compliance.

Academic and Industrial Research

Enables detailed study of battery thermal behavior, including gas generation, explosion pressure, and component analysis, facilitating material and system-level research.

Standards

The system is compliant with the following standard:

(1) UL 9540A-2025 – Standard for Testing Thermal Runaway Fire Propagation in Battery Energy Storage Systems

Parameters

Item	Specification
Platform Dimensions	Determined by sample volume requirements
Control Cabinet	650(L) × 675(W) × 1750(H) mm
Fourier Transform Infrared (FTIR) System	650(W) × 675(D) × 1750(H) mm
Power Supply	AC 220 V, 30 A
Weight	Approximately 900 kg
Backup Gas Source	Nitrogen ≥ 99.99%

Features

High-Strength Stainless Steel Vessel

304 stainless steel chamber ensures corrosion resistance, high-temperature durability, and mechanical integrity. Design pressure 3 MPa, constant operating pressure 2.5 MPa, with a safety valve for rapid pressure relief.

Multi-Channel Battery Parameter Monitoring

Supports online monitoring of voltage, temperature, and pressure through K-type high-temperature thermocouples and high-precision imported sensors, covering heating, overcharge, and nail penetration trigger modes.

Integrated Environmental Control

Vacuum extraction, nitrogen filling, exhaust, and oxygen concentration detection (0–100% Vol.) are included. Video monitoring allows real-time observation of thermal runaway events.

Automated Gas Sampling System

Multi-layer sample lines with real-time pressure monitoring ensure continuous, accurate gas sampling. Automatic switching prevents blockage and maintains system integrity.

Heated Sampling Lines

Prevents intrusion of liquid electrolyte into analytical instruments, reducing interference and improving gas composition measurement accuracy.

Advanced Gas Analysis

FTIR spectrometer and electrochemical sensors, combined with a professional analysis model, enable precise online measurement of complex gases produced during battery thermal runaway.

User-Friendly Control Software

Intuitive interface, low latency, real-time monitoring of gas composition, battery parameters, and environmental conditions.

Extended Data Processing

Automatic calculation modules for gas evolution rate and total gas volume, with seamless integration into the software for data visualization and reporting.

Accessories

(1) Multi-layer gas sampling lines

(2) Pressure and temperature sensors

(3) Vacuum pump and nitrogen supply interface

(4) FTIR spectrometer

(5) Electrochemical gas sensors

(6) Heated pipeline assembly

(7) Video monitoring system

(8) Control cabinet with PLC and touchscreen

Test Procedures

Sample Installation: Place battery cells into the pressure vessel and secure the chamber.

System Setup: Connect nitrogen supply and configure oxygen concentration requirements.

Parameter Configuration: Set monitoring channels for voltage, temperature, pressure, and gas analysis in the control software.

Initiate Thermal Runaway: Trigger the battery using heating, overcharge, or nail penetration methods.

Data Acquisition: Real-time monitoring of gas composition, internal pressure, temperature, and battery parameters. Automated calculation of gas evolution rate and total gas volume.

Observation and Recording: Monitor test via video feed and software interface.

Test Completion: Safely vent the vessel, retrieve battery cells, and store collected data for analysis and reporting.

Maintenance Information

Inspect vessel seals, flanges, and sampling connections regularly for integrity.

Calibrate temperature, pressure, and gas sensors periodically.

Clean sampling lines and FTIR components to prevent contamination and measurement errors.

Verify nitrogen supply, vacuum pump operation, and safety valve function before each test.

Backup all acquired test data and system logs for traceability and reporting purposes.

Conclusion

The In-situ Gas Analysis System for Lithium Battery Thermal Runaway provides a robust and fully integrated platform for triggering, monitoring, and analyzing thermal runaway events in lithium batteries. With real-time gas composition analysis, multi-parameter monitoring, and automated data processing, it enables accurate testing in compliance with UL 9540A-2025. supporting research, manufacturing, certification, and safety evaluation efforts.

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