Guardians Behind Energy: Gas Monitoring and Safety Alerts in the Battery Industry

With the global energy transition, the lithium and lead-acid battery industry has entered a phase of rapid growth. However, processes such as formation, charging, and electrolyte preparation generate flammable, explosive, and toxic gases due to complex chemical reactions.

From extremely light and explosive hydrogen to corrosive acid mist and sulfur dioxide, these invisible threats can compromise efficiency and cause fires, explosions, or occupational poisoning if not controlled. Nexisense leverages advanced gas sensing technology to provide a precise and intelligent safety monitoring system for the battery industry.

Battery Production “Hazard List”: Key Gas Analysis

1. Hydrogen (H2): The Lightest Explosive Threat

H2 is a common byproduct during battery charging and formation.

• Properties: Diffuses rapidly and accumulates at high points such as ceilings.

• Risk: Low explosion limit and minimal ignition energy; accumulation in ceiling corners can cause violent explosions if sparks occur.

• Nexisense Solution: High-level monitoring with strategically installed detectors on ceilings and upper structures.

2. Toxic Gases: Dichloromethane, SO2, and Acid Mist

• Dichloromethane: Used in separator production or cleaning; narcotic and toxic.

• Sulfur dioxide (SO2): Byproduct in lead-acid battery production; strongly irritates the respiratory system.

• Acid Mist: Corrosive vapor from electrolyte; harmful to personnel and equipment.

• Monitoring Principle: Nexisense follows a “toxicity first” principle, issuing alerts at low concentrations before explosive risks.

Nexisense Full-Stack Product Matrix for Battery Industry

SGA-500: Online H2/Toxic Gas Detectors

• High-level installation: lightweight, easily mounted on ceilings or beams to capture rising hydrogen.

• Long-term stability: imported sensors with high selectivity, resistant to interference from background industrial gases.

  
  

SGA-900: Pre-Treatment Monitoring System

• Dehumidification and corrosion protection: removes acid mist and excess moisture, protecting sensors and extending service life in lead-acid battery workshops.

SGA-700: Intelligent Sensor Modules

• Plug-and-play: easily integrated into battery aging cabinets and charge/discharge testers for native gas safety awareness.

SGA-600: Portable Inspection Detectors

• Mobile defense: allows inspectors to perform multi-gas measurements before entering formation rooms or material storage areas.

Hydrogen Monitoring: The “High-Level Rule”

• Installation height: 30–60cm below the ceiling; H2 rises rapidly due to its low density.

• Coverage of dead zones: additional monitoring points in beam intersections and low-ventilation areas.

• Linked ventilation: SGA-800 controller activates ceiling fans when H2 exceeds the warning threshold, dispersing accumulated gas.

Why Battery Manufacturers Choose Nexisense

• Multi-gas monitoring: H2, SO2, O2, and VOCs can be monitored simultaneously via RS485 digital integration.

• Strong interference resistance: excellent EMC performance ensures reliable data transmission in electrically noisy workshops.

• Corrosion-resistant housing: specialized coatings and three-proof circuits withstand acid mist corrosion.

• Smart modular design: sensors can be hot-swapped on-site without recalibration, reducing costs and improving efficiency.

  
  

Battery Production & Energy Storage Safety: FAQs

Q1: H2 is both flammable and extremely light. Are there strict installation requirements?
A1: Hydrogen is 1/14 the density of air. Detectors must be installed 30–60cm below ceilings, covering all beam recesses to prevent local accumulation and explosion risks.

Q2: Standards require “toxicity first,” but hydrogen is often monitored for explosiveness. Is this contradictory?
A2: Not contradictory. In densely occupied areas, ppm-level electrochemical sensors follow “toxicity first,” alerting at 100–500ppm. In unoccupied zones, %LEL catalytic or IR sensors focus on explosion prevention. SGA-500 supports dual-range monitoring for both health and fire safety.

Q3: Acid mist often poisons or damages sensors in lead-acid workshops. What solutions exist?
A3: Active (SGA-900): sampled gas passes through multi-stage neutralization filters and moisture separators. Passive: sensors wrapped with PTFE anti-corrosion membranes, with periodic replacement.

Q4: Why use PID sensors for dichloromethane instead of semiconductor sensors?
A4: Dichloromethane is halogenated and toxic. High-precision PID sensors detect 0.01ppm in<3s, unaffected by humidity or other solvents.

Q5: How to position sensors in compact battery aging cabinets with strong EMI?
A5: Use SGA-700 smart modules embedded in cabinets; multi-stage optical isolation ensures EMC robustness and reliable readings.

Q6: Which gases besides H2 should be monitored in ESS containers?
A6: CO, H2, VOCs; multi-sensor fusion detects anomalies minutes before thermal runaway, aiding automatic fire suppression.

Q7: How to integrate Nexisense signals into factory digital systems?
A7: Standard RS485 (Modbus RTU) allows hundreds of detectors to connect to PLC/DCS; 4G/5G or LoRa wireless options available for legacy plants.

Q8: How to comply with increasingly strict safety audits?
A8: Nexisense devices hold explosion-proof and calibration certificates. Logs store 1000+ past alarms and calibrations; sensors feature “end-of-life alerts” for proactive maintenance.

Conclusion

Gas safety in the battery industry involves managing extremely light gas accumulation and corrosive environments. Nexisense provides precise sensor placement, advanced pre-treatment, and intelligent integration to create a digital safety barrier from production lines to the cloud.

If you are concerned about hydrogen accumulation in formation workshops or safety compliance in energy storage containers, contact Nexisense industry experts for customized monitoring layouts and complete hardware/software integration solutions.