The surge in electric vehicle (EV) battery manufacturing in the United States is ushering in a new wave of chemical risks for American workers. The case of Ultium Cells LLC’s new battery plant in Warren, Ohio—joint venture between LG Energy Solution and General Motors Co.—is particularly illustrative. The plant has seen numerous incidents, including fires, inhalation of chemical fumes, and potent acid spills. The Fire Chief, Travis Eastham, criticized the company’s training sessions for first responders, which he described as inadequate, and cited an explosion in March 2023 as an example of the severe safety oversights. Ultium was fined $270,000 for 19 safety violations by the US Occupational Safety and Health Administration (OSHA), a decision currently being contested.
Lithium-ion batteries, while heralded for their role in reducing automobile emissions, pose significant health risks due to the hazardous chemicals involved in their production. According to OSHA, violations in the sector rose to 47 in 2024, already surpassing the previous year’s count. Among the companies cited were Ultium Cells, SK Battery America, and LG Energy Solution Michigan Inc.
The risks are not confined to fires alone. Workers are exposed to a variety of hazardous substances during different stages of battery production. Creating electrodes involves the use of powdered metals like nickel and cobalt mixed with liquid solvents, which necessitate extensive protective measures. The assembly process also involves toxic chemicals and acids, further compounding the risks. For example, SK Battery’s plant in Georgia faced OSHA citations for a fire incident that exposed workers to hydrofluoric acid vapors and revealed first responders’ lack of preparedness for battery-specific hazards.
Adding to the complexity is the fact that many of these chemicals lack long-term exposure studies, and OSHA guidelines do not cover all hazardous materials commonly used in battery manufacturing. The industry, thus, often depends on its own safety protocols, which sometimes fall short. Companies like Tesla have had to exceed OSHA requirements to ensure worker safety, given the agency’s slow-moving regulatory framework.
Additionally, the dynamic and secretive nature of battery formulations adds another layer of difficulty in protecting workers. As Ultium demonstrates, incidents and consequent injuries have been a learning curve for the emerging industry. Despite numerous challenges, there has been progress. Eastham noted that his department receives fewer emergency calls now, reflecting some improvements in safety protocols and injury management.
The US is still in the early stages of this industry, and as such, there are significant unknowns and ongoing learning processes to handle the chemical risks specific to EV battery production. The importance of proactively developing and sharing best safety practices cannot be overstated if the industry is to safeguard its workforce effectively.
For further details, visit the original article on Bloomberg Law.