The Core Value and Application Scenarios of Explosion-Proof Battery for Forklift

In chemical, petroleum, gas, and dusty operations, air can be dangerous due to the mixing of flammable substances. In those spots, a regular forklift can act like a moving ignition source. Sparks, hot parts, or static can light off vapors or dust, so controls and protected equipment matter.

That’s why sites use hazardous-area rules like ATEX/IECEx or NEC classes to limit ignition from trucks and their electrics. ROYPOW recognizes how serious these incidents can be and has launched a new forklift lithium-ion battery with explosion protection, which is specifically designed for these hazardous areas. This article will explain its core value and applicable scenarios.

Forklift Battery Explosion Causes

1. Electrical Sparks

Arcs can occur between contacts, relays, and connectors when a truck starts, stops, or connects to a load, and this arc can cause a flammable mixture to become ignited. So, only specific types of trucks are permitted to go into classified areas.

2. Surface High Temperatures

When the surface temperature of a vehicle component (such as the engine, exhaust system, braking resistor, or even the motor housing) is higher than the ignition point of the surrounding gas or dust, it constitutes a potential ignition source.

3. Friction and Static Electricity Sparks

If bonding and grounding are not in place, hot particles may be thrown by activities such as tyre slide, dragging forks, or metal strikes. Insulated parts or persons can also build up charge and discharge if these activities occur.

4. Battery Internal Faults

Within flammable and explosive atmospheres, a forklift battery poses a significant hazard as a standalone unit, with lead-acid batteries being particularly risky due to their intrinsic properties.

(1) Hydrogen Gas Emission

The lead-acid battery charging process leads to electrolysis of dilute sulfuric acid through electrical energy input. This results in hydrogen gas formation at negative plates and oxygen gas formation at positive plates.
Hydrogen has a broad flammability range that spans from 4.1% to 72% in air^[1] and requires very little ignition energy at 0.017 mJ.
A complete charge cycle of a big battery system produces a large amount of hydrogen. The enclosed or poorly ventilated charging area or warehouse corner allows hydrogen to build up explosive concentrations at a fast rate.

(2) Electrolyte Spills

Sulfuric acid electrolyte can be easily splashed or leaked during routine maintenance activities such as replacement or transportation of the battery.

Multiple Hazards:

Corrosion and Chemical Burns: Spilled acid is a highly corrosive which can damage the battery tray, forklift chassis, and flooring. It also poses a risk of severe chemical burns to personnel upon contact.
Electrical Short Circuits and Arcing: The sulfuric acid electrolyte shows excellent electrical conductivity properties. When it spills onto the battery top or into the battery compartment, it can create unintended conductive paths for electrical current. This may cause short circuits, generating intense heat and dangerous arcing.
Environmental Contamination: Its cleanup and neutralization process generates wastewater, creating secondary environmental issues if not handled properly.

(3) Overheating

Overcharging or excessively high ambient temperatures can cause the battery temperature to spike. If the heat cannot be dissipated, lead-acid batteries may even experience thermal runaway.

(4) Maintenance Hazards

Routine maintenance operations (such as adding water, replacing heavy battery packs, and connecting cables) are inherently accompanied by risks of squeezing, liquid splashing, and electric shock, increasing the possibility of human error.

How ROYPOW Explosion-Proof Battery Builds a Safety Defense

Our ROYPOW explosion-proof battery is designed and manufactured in strict accordance with ATEX and IECEx explosion-proof standards and undergoes rigorous third-party testing, ensuring safe operation in areas containing flammable gases, vapors, or combustible dust.

Internal Explosion-Proof Safety: The battery and electrical compartments use sealed and rugged construction, which protects against internal fires and explosions while maintaining reliable operation.
Reinforced External Protection: Explosion-proof cover and casing feature high strength to effectively handle shock and vibration, providing extra protection.
Intelligent Management: The BMS monitors the forklift battery cells’ status, temperature, and current, and disconnects in case of faults. An intelligent display shows relevant data in real time. It supports 12 language settings for easy reading and enables upgrades via USB.
Long Lifespan and High Reliability: The LiFePO4 forklift battery pack incorporates Grade A cells from the world’s top 10 brands. It has a design life of up to 10 years and over 3,500 cycles, delivering durable and stable operation even under harsh conditions.

Core Value of ROYPOW Explosion-Proof Battery

1. Enhanced Safety and Reliability

We start with safer chemistry and enclosures, and add tested explosion protections for risky areas. Our explosion-proof battery limits ignition sources and keeps pack temperatures in check.

2. Compliance Assurance

We design to accepted standards of explosive atmospheres (ATEX/IECEx) for our battery packs.

3. Operational Efficiency Optimization

High charge-discharge efficiency and opportunity charging let crews run longer between stops for multi-shift use without battery swaps. Your forklift battery stays in the truck and on the job.

4. Zero Maintenance and Lower TCO

No routine watering, no acid cleanup, and fewer service tasks cut labor and idle time. The explosion-proof battery pack is virtually maintenance-free, contributing to significant long-term savings in labor and maintenance costs.

5. Environmental Sustainability

Switching from lead-acid helps trim operational emissions. This lithium-ion forklift battery shows up to a 23% annual CO₂ reduction and produces zero emissions at the point of use.

Application Scenarios of ROYPOW Explosion-Proof Battery

Petrochemical Industry: Refineries, chemical plants, hazardous material warehouses, and other locations with flammable gases or vapors.
Grain and Food Processing: Flour mills, sugar powder workshops, and other environments with combustible dust clouds.
Pharmaceutical and Chemical Industry: Raw material workshops, solvent storage areas, and other zones involving flammable and explosive chemicals.
Aerospace and Military Industry: Paint spray workshops, fuel assembly areas, and other special locations with extremely high explosion-proof requirements.
Urban Gas and Energy: Gas storage and distribution stations, liquefied natural gas (LNG) facilities, and other urban energy hubs.

Invest ROYPOW to Upgrade your Forklift Safety

In summary, the inherent high risks of conventional forklifts and the lead-acid power sources in flammable and explosive environments cannot be overlooked.

Our ROYPOW explosion-proof battery integrates robust internal and external protection, intelligent monitoring, and proven reliability into a fundamental safety solution for material handling in hazardous areas.