Milan Malpensa airport was temporarily closed after an Airbus A320 bound for Prague was evacuated on the taxiway due to the presence of smoke in the cabin. At the origin of everything there was a faulty power bank, kept in hand luggage. cabin. There were 146 passengers on board, who were taken down the inflatable slides: two of them were slightly bruised.
The accident occurred yesterday, September 10, around 5.30pm and the airport was partially reopened after about an hour. It is not the first time, however, that episodes of this type have occurred on board aircraft: power banks, in fact, contain lithium batteries, which can trigger a phenomenon called thermal runaway (or thermal runaway), i.e. an uncontrolled and self-sustained increase in pressure and temperature which self-feeds the fire.
An in-depth analysis of this chemical-physical process is available in this video of ours, but for those traveling by plane it is important to know in advance the rules for bringing a power bank on board and, above all, what procedure to follow if our portable battery starts to overheat or swell.
However, it should be remembered that, in itself, it is not the pressurized environment of the aircraft that causes the ignition: power banks can overheat and generate flames only if they have manufacturing defects, if they are damaged, overloaded or exposed to extreme temperatures.
Powerbanks and batteries on planes: the rules to follow
The first rule is clear and does not allow exceptions: power banks must travel in hand luggage, located in the cabin, and never in the hold. This is because any overheating in the cabin can be noticed and addressed immediately, while in the stowed luggage it would remain hidden and out of control.
From 27 March 2026, ICAO (the International Civil Aviation Organization) has introduced more stringent rules on the transport of these portable batteries on board an aircraft. In particular, only two power banks are now allowed per passenger, with a capacity of no more than 100 Wh each. In case of capacity between 100 Wh and 160 Wh, a specific authorization from the company is required, while above 160 Wh these batteries are prohibited.
Power banks must then be separated from other types of batteries and are prohibited from recharging them during the flight.
In addition, these batteries must be individually protected during travel to avoid short circuits while not in use. In practice, protecting them means leaving them in the original packaging, covering the terminals with tape, or placing each in a separate case or plastic bag.
The FAA, however, reminds you that many airlines, both national and international, apply even more stringent limits for power banks: the advice, therefore, is to always check the company’s rules before leaving.
What passengers should do if a powerbank starts to overheat
At this point, what should we do if our powerbank starts to overheat or swell? The first rule is as simple as it is decisive: immediately notify a crew member. The FAA is explicit in recommending that passengers immediately report to flight personnel if the battery or device is overheating, swelling, emitting smoke or burning.
However, there is also a preventive behavior that makes the difference, and it concerns where we keep the powerbank during the flight. The Safety Alert for Operators The FAA in fact underlines a crucial point: batteries placed in overhead bins or inside closed hand luggage can remain obscured, without being monitored by either passengers or crew and thus becoming difficult to reach in case of emergency.
This is exactly the scenario of the Malpensa accident, with the exploded powerbank which, according to initial information, was inside a trolley. When this happens, the detection of the thermal runaway and the shutdown operations risk arriving late, with the risk of having to evacuate the plane as in this recent case.
For this reason, the recommendation is to keep these devices in a visible and accessible point, where any onset of overheating can be immediately noticed and managed.
Crew safety procedures: Cool the device to stop thermal runaway
At this point we get to the heart of the matter: how does the crew intervene to secure the powerbank? To understand this, we must first remember that the thermal runaway it is considered an uncontrolled, self-sustaining increase in pressure and temperature. The key word is “self-sustaining”: once triggered, the reaction powers itself and continues until all the battery cells have completely discharged their energy.
Intuitively, one would think that a fire extinguisher would be enough to solve the problem by putting out any fire, but this is not the case. The FAA explains that the Halon extinguishers on board can briefly suppress the flames, but do not stop the thermal runaway process. Turning off the flame without cooling the battery means leaving the chemical engine intact which continues to produce heat, ready to re-ignite.
The crew’s priority, therefore, is to cool the device, using large quantities of water to cool the battery and at the same time douse the flames. Cooling with water is essential because it is the only way to prevent the reaction from continuing, causing the battery to safely exhaust its energy.
Given the increased frequency of this type of accident, the FAA has recommended that companies review procedures, crew training and equipment. Operators, in particular, should:
- Ensure crew members recognize the different stages of lithium battery thermal runaway (e.g. smoke versus flame) and can respond appropriately;
- Evaluate onboard safety equipment, such as fire extinguishers, water sources and fire containment products, to ensure that it is capable of mitigating onboard fires caused by lithium batteries;
- Evaluate aircraft components, emergency equipment and passenger items that could be affected by a thermal runaway event;
- Review procedures to minimize the risk of smoke inhalation by passengers and crew members.
At the same time, in-flight safety communications should be reviewed to also include the management of power banks, providing passengers with information on the safe handling, stowage and transport of lithium batteries, including how to prevent them from being crushed or damaged.
