Bulging lithium-ion batteries signal malfunctions that can lead to dangerous fires, with incidents surging at recycling centers. A 2024 report highlights over 5,000 annual fires caused by improper disposal, prompting calls for specialized handling. Experts urge immediate safety measures and responsible recycling to mitigate risks and support a growing market projected to reach $98.42 billion by 2034.
Lithium-ion batteries power everyday devices like smartphones, laptops, and electric vehicles, but failures can produce toxic fumes and fires. A bulging battery, often doubling in thickness, may warp devices such as causing an iPhone to pop open or raising a laptop's keys. Other warning signs include excessive heat, leaking chemicals with a strong odor, rapid draining, or unexpected shutdowns.
Fires at U.S. and Canadian waste facilities rose 15% in 2024, from 373 to 430 incidents, according to Fire Rover data—the highest since tracking began in 2015. The National Waste & Recycling Association and Resource Recycling Systems reported over 5,000 yearly fires at recycling centers, largely from discarded batteries. A 2025 UL Standards & Engagement survey found 36% of consumers toss old batteries in trash and 30% in curbside recycling, both hazardous practices.
To handle a bulging battery, unplug the device, power it off, and avoid charging. Ventilate the area, tape exposed terminals with non-conductive material, and label the container as containing a damaged lithium battery. Never puncture it, as this risks thermal runaway and explosion. If leaking, remove outdoors, use sand or kitty litter for containment, wear protective gear, and avoid water—lithium reacts corrosively. For fires, deploy an ABC extinguisher.
Store in a cool spot between 40 and 80°F in a fireproof container, and dispose within 90 days. Standard programs like Call2Recycle exclude damaged batteries; instead, use local hazardous waste facilities, Call2Recycle's DDR kits (up to 4.4 lbs combined or 11 lbs single), or Cirba Solutions for larger volumes. Manufacturers like Apple and Samsung offer take-back for warranted devices, while the EPA plans a lithium-specific universal waste rule by August 2027.
Demand surges as recycling material is set to hit 1.4 million tons by 2030, up from 200,000 in 2020. Over 80% of processing occurs in China, underscoring global sustainability needs.
