Modern Problems Require Modern Solutions: Battery Fires and Robotics

Summary: Waste, recycling plants, and transfer stations operate inside tall, high-volume buildings where ignition sources—especially lithium-ion batteries hidden in the stream, deep-seated heating in organic piles, volatile containers, and mobile-equipment sparks—can turn small incidents into costly multi-alarm fires. Because ceiling sprinklers are heat-activated, activation can be delayed by distance and stratification in these spaces. Meanwhile, publicly reported, catastrophic facility fires in the U.S. and Canada climbed from 373 in 2023 to 430 in 2024, with MRF/transfer-station fires up ~20% year over year, underscoring the need for earlier, targeted intervention and the adoption of new technologies.

MRF Fire

What this article covers:

• Why MRFs and transfer stations are uniquely vulnerable to battery, heat-buildup, and other fire scenarios

• How building physics (tall volumes, airflow, stratification) delay sprinkler activation

• Recent, verifiable facility fires (since 2023) illustrating the risk landscape

• Practical prevention and response steps you can implement now

• Where robotic, targeted suppression fits as a suitable, effective solution

1) Why these facilities are uniquely vulnerable

Lithium-ion batteries in the waste stream. Today, we come into contact with thousands of batteries in our everyday lives, per week. Nearly every modern electronic device as some sort of battery component--consider that Apple AirPods have three batteries alone. These items, along with vapes, tool packs, e-bikes, laptops, and phones are routinely mis-thrown into trash and curbside recycling. When punctured, crushed, or shorted on conveyors or in compactors, cells can vent, enter thermal runaway, and ignite. The U.S. EPA explicitly instructs that Li-ion batteries must not go in household trash or curbside bins; instead, tape terminals/bag cells and take them to dedicated drop-off or Household Hazardous Waste (HHW) sites.

Heat build-up & spontaneous combustion (Class A). Cardboard, textiles, paper, green waste, and mixed organics can self-heat in large piles, especially with poor ventilation and elevated moisture, leading to deep-seated ignition that’s hard to access. (Operational guidance from state and technical agencies emphasizes pile sizing, temperature monitoring/turning, and ventilation.)

Mixed volatiles in the stream. Aerosol cans, small propane cylinders, oily rags, and loose button cells can escalate otherwise routine fires with pressure events or rapid flame spread—now flagged in many municipal/industry advisories.

2) The building-physics problem: why sprinklers can be late

Sprinklers remain essential life-safety controls, but they’re heat-triggered. Ordinary and intermediate-temperature heads typically actuate around 135–170°F (57–77°C). In high-bay MRFs/transfer halls, plume cooling, stratification, large air volumes, doors, and HVLS fans can delay heat delivery to the ceiling, slowing activation when early knockdown matters most. (NFPA provides the temperature classifications; warehouse design discussions highlight ambient limits and stratification concerns.) NFPA

Bottom line: sprinklers excel at area control, not ultra-early pinpoint suppression at floor level or inside a bunker/conveyor pocket.

3) The trend line: fires are rising, and batteries are a major driver

Across all facility categories in the U.S. and Canada, publicly reported fires rose from 373 (2023) to 430 (2024)—the highest annual figure since tracking began. Incidents at MRFs/transfer stations increased about 20% year over year. Industry reporting attributes a significant share of the risk to lithium-ion batteries. Resource-Recycling

4) Recent, verifiable incidents (since 2023)

These examples show the breadth of risk across transfer stations, MRFs, and recycling operations. (Dates are local.)

• Apr 11–16, 2023 – Richmond, Indiana (plastics recycling/warehouse). Massive fire prompted evacuation orders for ~2,000 residents and multi-day EPA air monitoring. richmondindiana.gov

• May 31–Jun 1, 2023 – Milwaukee, Wisconsin (Joint MRF). Three-alarm sorting-floor fire shut down operations; no injuries reported. City of Milwaukee

• Jun 24, 2024 – Portland, Oregon (Metro Central Transfer Station). Deep-seated debris-pile fire inside transfer station required significant suppression effort. https://www.kptv.com

• Aug 28, 2024 – Queens, New York (barge at Sims Metal). FDNY fire marshals determined a lithium-ion battery sparked the barge blaze on Newtown Creek. QNS

• Jul 9, 2024 – Oneida County, Wisconsin (transfer station). Early-morning transfer-station fire; sheriff’s office documented the facility impact.

  
  

(These are U.S. examples; similar incidents continue globally.)

5) Practical steps to lower your risk now

• Battery triage by design. Establish dedicated battery-collection and quarantine points at the tip floor entrance; train scale-house and floor staff to spot “red flags” (e-bikes, scooters, loose packs). Align signage with EPA messaging to keep Li-ion out of bins. US EPA

• Pile management & monitoring. Enforce maximum pile dimensions; track core temperatures; turn or break down piles trending hot; ventilate enclosures to prevent trapped heat. https://www.kptv.com

• Conveyor & bunker vigilance. Focus early detection on bunkers, screens, shredders, and transfer points where mechanical energy can damage cells.

• Pre-incident planning. Coordinate with local fire agencies on access paths, hydrant/standpipe layouts, and isolation/shutdown procedures; run drills for battery-origin events.

• Layered protection. Treat sprinklers (NFPA 13) as the last line for area control; add earlier-stage detection and targeted suppression at floor level and in high-hazard zones. NFPA Robotic Nozzles and Autonomous Fire Suppression can act as a first line of suppression defense, keeping operations on line and people safe.

6) Where robotic, targeted suppression fits (and why it helps)

Early, directed water streams onto the seat of the fire buy the most precious commodity in fire response—time—while reducing water damage and downtime compared with broad-area discharge.

If you would like to learn more about robotic and autonomous fire-fighting systems, keep reading and feel free to contact us. WatchDog Robotics designs detection-driven, precision-delivery systems that continuously scan large floorplates and bunkers with multi-sensor analytics. Our systems detect an 8-inch flame in 15 seconds or less across nearly two football fields of monitored area and automatically apply a tight, targeted stream of water to the ignition point—often long before ceiling sprinklers would activate. This approach helps protect people and equipment, limit operational disruptions, and reduce disruptive emergency callouts. (We can integrate with existing alarms, cameras, and E-stops and complement, not replace, your NFPA-required systems.)

Want specifics for your site? We can map coverage to your tip floor, bunkers, conveyors, and bale lines; estimate response time advantages; and provide a comprehensive protection plan. Contact WatchDog Robotics or call today (307-231-0416) to explore a design review or pilot deployment. Precision Fire Suppression that is Rapid, Smart & Simple.

Rumpke Transfer Station Fire