Four Types Of Harmful Gases Commonly Found In The Battery Industry

2025-09-24 03:08:09

(MENAFN- GetNews)

The following harmful gases are mainly present in the production, testing, storage and recycling of the battery industry:

1. Volatile Organic Compounds (VOCs)

N-Methylpyrrolidone (NMP): Volatile in large quantities during electrode slurry preparation and coating and drying processes, reaching concentrations of 5,000-10,000 mg/m3, accounting for 60%-80% of the total VOCs in lithium battery exhaust.

Carbonates (DMC, EC, etc.): Volatile during electrolyte preparation and injection processes, with concentrations fluctuating between 100-500 mg/m3.

Aldehydes and ketones (such as formaldehyde and acetone): Volatile during POM processing and adhesives, and are highly irritating.

2. Acidic Gases

Hydrogen Fluoride (HF): Produced by the hydrolysis of lithium hexafluorophosphate. Highly corrosive, with concentrations reaching 50 mg/m3.

Hydrogen Chloride (HCl): Released during the decomposition or recovery of chlorine-containing additives, with concentrations ranging from approximately 10-50 mg/m3.

3. Flammable and Toxic Gases

Hydrogen (H2): Produced by electrolyte decomposition or cathode reactions. Its lower explosion limit is low (4%) and requires close monitoring.

Carbon Monoxide (CO): Produced by decomposition in the early stages of battery thermal runaway. It is highly toxic and can easily cause fires.

Carbon Dioxide (CO2): Produced by electrolyte combustion or decomposition. High concentrations can cause asphyxiation.

4. Other Hazardous Gases

Silane: A decomposition product of coupling agents used in separator coating. It is flammable and explosive.

Sulfur-Containing Organic Compounds: Methyl mercaptan and other substances released during recycled batteries are highly toxic.

Different battery types (such as lithium-ion, lead-acid, nickel-cadmium, etc.) and process steps (coating, injection, formation, recycling) will produce specific harmful gas combinations, which require targeted monitoring and control.

The battery production process (such as lithium-ion, lead-acid, and nickel-metal hydride batteries) involves multiple steps, including electrode preparation, electrolyte injection, formation and aging, welding, and packaging. These steps can easily generate toxic, hazardous, or flammable and explosive gases, such as hydrogen, carbon monoxide, hydrogen fluoride, and volatile organic compounds (VOCs). Installing a gas detector is a necessary measure to address industry safety concerns, safeguard personnel health, and maintain production stability. Its core value lies in risk prevention and control, compliant production, and cost optimization.

Scientific Risk Prevention Guide: Gas detectors can accurately detect gas risks at every stage of battery production. Through a "tiered early warning + coordinated response" approach, accidents can be nipped in the bud:

Early Warning of Hazardous Gases: During the lithium-ion battery electrolyte injection process, detectors monitor hydrogen fluoride and NMP concentrations in real time. When hydrogen fluoride exceeds 0.5 ppm (Level 1 warning), an audible and visual alarm is triggered in the workshop, reminding personnel to wear gas masks. When the concentration exceeds 2 ppm (Level 2 warning), the local exhaust system (exhaust rate ≥ 2000 m3/h) is automatically activated to prevent inhalation poisoning.

Preventing Explosion Accidents: Hydrogen detectors are installed in the lead-acid battery charging area and lithium-ion battery drying room. The lower explosion limit is set to 10% (i.e., hydrogen concentration > 0.4% Vol) as the warning threshold. If the limit is exceeded, the power supply to the area is immediately cut off (to prevent static sparks) and explosion-proof exhaust ventilation is activated. In 2024, a battery factory successfully avoided an incident with a hydrogen concentration of 1.2% Vol. Explosion risk;

Locating the leak source: In the battery electrode coating workshop, multiple VOCs detectors were installed along the NMP delivery pipeline and coating oven. By comparing concentrations at various points (e.g., concentration at point A: 120 mg/m3, concentration at point B: 30 mg/m3), the leak point (e.g., aging of the pipeline flange seal at point A) was quickly located, shortening leak response time from 2 hours to 30 minutes.

On-Line Gas Detector

Technical Specification

Detecting Gas	Methane, hydrogen sulfide, carbon monoxide, oxygen (optional)
Detection Principle	Catalytic combustion type, electrochemical type, light ion type, thermal conductivity type, infrared NDIR type
Display Type	Four-digit LED high brightness digital tube
Power Supply	24VDC (normal working voltage range: 10 ~ 30VDC)
Power Consumption	<1.5W(toxic gas);<2.5W(combustible gas)
Output Signal	Three-wire 4 ~ 20mA or four-wire RS485 or both output at the same time; Two passive relay (24VDC 2A)
Work Environment	Temperature range:-20°C ~ 50°C(toxic gas)-40°C ~ 70°C(combustible gas) Humidity range: 10 ~ 95%RH (no condensation)
Sampling Mode	Diffusion type	Response Time	T90<30s(combustible gas)
Pressure Range	86~106kPa	Accuracy	± 3% F.S.
Protection Level	IP66	Main Material	Aluminum alloy
Product Size	185137.290.7mm(LWH)	Product Weight	About 1.6Kg
* For custom gases, please contact us for a selection sheet

Product Advantages

Four high bright digital tube LED display.
Intelligent sensor, modular design, easy maintenance.
Multi-point calibration + temperature compensation, more accurate data.
One key to restore factory settings to prevent misoperation.
4~20mA, RS485, wireless output signal optional, Triple waterproof design
Three indicators for power, fault and alarm.
Installation: wall - mounted, horizontal pipe, vertical pipe.
Infrared remote control operation, avoiding open cover operation on dangerous occasions.

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