On December 25, 2023, two significant fires broke out aboard the Panama-flagged bulk carrier Genius Star XI due to improperly secured lithium-ion battery cargo during heavy weather conditions. The National Transportation Safety Board (NTSB) investigation revealed that the vessel, carrying 192 battery energy storage system (BESS) units, faced severe weather with gusts exceeding 30 knots and swells reaching 19 feet. Failures in the lashing belts allowed 41 battery units to shift, causing internal structural damage and triggering thermal runaway in three units, which led to uncontrollable heating.
The investigation pointed out a critical flaw in the securing equipment. It was determined that the D-ring and hook used for securing were incompatible, resulting in a failure to securely hold the cargo. This design issue concentrated loads at the hook’s bend, causing it to fracture under stress. The crew attempted to combat the first fire using the vessel’s carbon dioxide fire suppression system but later encountered a second fire due to inadequate CO2 reserves.
Ultimately, the Genius Star XI anchored near Dutch Harbor, Alaska, on December 29. The incident raises serious concerns about the maritime transport of large-scale lithium-ion batteries, especially given that this flawed securing plan had been previously employed without issues in other similar transports. The NTSB emphasized the importance of thorough cargo inspection and adherence to securing guidelines to prevent such incidents in the future.
