B767-600 CREW RETURNED TO THEIR DEP STATION WITH SMOKE AND FUMES IN THE COCKPIT AND CABIN.

Narrative

CLBING THROUGH 6000 FT MSL COCKPIT CREW SMELLED BURNING ODOR AND CONFIRMED FUMES/HAZE IN CABIN AS WELL. CAPT TOLD FLT ATTENDANTS TO PREPARE FOR IMMEDIATE RETURN AND LNDG IN APPROX 5 MINS; NO EVAC PLANNED FOR LNDG. CAPT DECLARED EMER AND REQUESTED IMMEDIATE RETURN TO DCA. CAPT HAD COPLT GO ON EMER 100% OXYGEN AND FLY ACFT WHILE CAPT HAD OXYGEN AT READY; BUT DID NOT USE. CAPT WANTED TO MAXIMIZE CLR COMS BTWN DCA AREA CTLRS; COCKPIT AND CABIN. DID NOT WANT MUFFLED COMS TO CONFUSE DCA CTLRS AND MAKE THEM MISTAKE FOR COCKPIT CONFLICT/TERRORIST THREAT IN DCA AIRSPACE. SINCE DCA/IAD WERE EQUAL DISTANCE CAPT ELECTED RETURN TO DCA BECAUSE COPLT WAS MORE FAMILIAR WITH DCA FOR RAPID SHORT FIELD APCH. ALSO; ANDREWS AFB WAS EQUAL DISTANCE ON DOWNWIND IF SIT REQUIRED LNDG SOONER THAN DCA. COPLT EXCEEDED 250 KTS BELOW 10000 FT ENRTE DCA. FUMES CONTINUED AND CAPT INITIATED SMOKE/FUME REMOVAL PROCS UNTIL LNDG IMMINENT; THEN CONCENTRATED ON LNDG CHKLIST. SWITCHED TO DCA TWR AND NOTIFIED TWR I WOULD TURN IMMEDIATELY INTO ADJACENT COMPANY GATES; OTHER THAN EVACUATING ON RWY. VISIBILITY AND AIR QUALITY STILL ADEQUATE AND SOMEBODY ALWAYS GETS HURT IF SLIDES ARE USED. TIME FROM RWY TO GATE WAS APPROX 20 SECONDS. COMPANY RAMP STAFF STANDING BY AND IMMEDIATELY PULLED UP FORWARD DOOR JETWAY AND AFT AIRSTAIR TO REAR DOOR AND WE EXPEDITIOUSLY DISEMBARKED ALL 89 PAX AND 6 CREW; AND SHUT DOWN ACFT -- NO INJURIES RPTED. SOURCE OF FUMES/SMOKE WAS FOUND TO BE BATTERY CELL MELTDOWN/BATTERY CHARGER MALFUNCTION WAS INITIAL ASSESSMENT. CAPT USED NON STANDARD OXYGEN MASK PROCS; MAX AIRSPD; NON STANDARD EVAC DUE TO HIS JUDGEMENT TO MAXIMIZE COM; AND MINIMIZE THE AIRBORNE AND MINIMIZE POTENTIAL FOR INJURIES.