A US flight was evacuated prior to takeoff when a passenger’s Galaxy Note 7 — reportedly a replacement in Samsung’s global recall — caught fire, landing the company in new controversy.

Samsung has been struggling with a recall of 2.5 million Galaxy Note 7 handsets due to complaints of exploding batteries, a problem the replacement phones are supposed to fix.

 But on Wednesday, a Southwest Airlines flight leaving Louisville, Kentucky was evacuated after a passenger’s new Samsung phone began emitting smoke.

Brian Green, the owner, told tech news website The Verge that the phone was a replacement, which he picked up on September 21. He also provided a picture of its box, which has a black square symbol indicating that it was a replacement. Some 60 percent of US consumers had swapped their devices for replacements by the end of last month.

The Verge reported Green had powered down the phone for takeoff, an account The New York Times confirmed through other eyewitnesses.

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