Reliable measurement even in corrosive, hazardous battery recycling environments

The shift to electric vehicles is reshaping industry at pace, and with it comes a new challenge the sector has to face: what happens to the batteries when the vehicles reach end of life? A UK company at the forefront of answering that question set out to build a facility capable of recovering the critical materials locked inside spent EV batteries and returning them to productive use.

The process takes the end-of-life EV batteries and mechanically separates them to produce black mass: a material rich in lithium, nickel, cobalt, manganese, and graphite. Leachates and acids are then used to break this down further into its constituent parts, which are pumped to separate tanks and recovered for reuse in new battery production. The result is a genuine closed loop, supporting the UK's EV supply chain from the ground up.

From an instrumentation perspective, the challenges were considerable. The facility handles a wide variety of highly corrosive chemicals simultaneously. The nature of the process means hazardous area classifications like ATEX may be applicable. 

When the team began looking for an instrumentation supplier, their requirements went beyond a product catalogue. They wanted a single, trusted partner who could engage from day one.

VEGA stood out due to the unwavering reputation for level sensors. The team was also proactive in coordinating with the customer, ensuring time was taken to understand their goals and mission before coming up with a tailored solution to their process. That approach — curious, committed, and commercially aware — was exactly what this operation needed.

Further to that, the technical specifications VEGA was able to offer for this application were unmatched, coupled with the strong after sales support provided, the choice of supplier was not just about the products, it was about having a reliable partner by their side.

The VEGABAR 28 and 38, part of VEGA's BASIC series, were selected for continuous pressure measurement across several critical points in the process. Inside the scrubber systems they keep conditions stable and the process running consistently. On the leach tanks, where aggressive acidic media are present, accurate and reliable measurement is essential to process control. The same instruments are used on pumps throughout the facility to monitor pump health and catch any issues before they affect operations.

Choosing the right specification matters especially for processes such as this, and the BASIC series delivered exactly the right balance. For the pressure instruments, the ceramic measuring cell provides the chemical resistance the process demands, while PVDF wetted fittings ensure compatibility with the full range of corrosive substances on site. The VEGAPULS 21/31 radar sensors bring their own resilience to the application — non-contact measurement meaning the aggressive media presents no risk to the instrument itself, ensuring continuous, reliable level measurement in critical process points.

Across both, accuracy meets the requirements of the application, and the option of ATEX approval means the instruments are rated for the hazardous areas created by the process chemicals present throughout the facility. Intrinsic safety is a baseline requirement in an environment like this, not an optional extra, and the BASIC series meets it without adding unnecessary cost or complexity.

The project followed a deliberate, phased approach and it is where the simplicity of the VEGA instrumentation proved its worth in practice.

Commissioning was handled entirely in house. The customer's own team configured the devices using the free VEGA Tools App, with the Backup and Restore functionality ensuring settings could be preserved and replicated reliably as the operation grew.

VEGA's broader support throughout the project, including lead times and after sales support, drew specific praise as a meaningful differentiator from other suppliers.

With the process proven and the operation now running at scale, attention is turning to what comes next. The facility is continuing to expand its capabilities, with VEGA written into the plant specifications — a clear signal of the confidence that has built up over the course of the relationship.

The southwest of England is establishing itself as a hub for the UK's battery supply chain, with lithium mining activity, gigafactory development, and a growing concentration of EV-related industry across Cornwall and Somerset.

What began as a first response to an enquiry has grown into exactly the kind of relationship VEGA aims to build: trusted, technically credible, and built to last. A proactive start, the right products for a genuinely demanding application, and a commitment to being genuinely useful at every is what made the difference here, and what will carry the partnership forward.