POWERING EV GROWTH

SUMMARY

When a major global EV battery producer expanded its U.S. operations in the Midwest to support the rapidly growing electric vehicle market, it faced a critical environmental challenge. The battery washing process—an essential step in lithium-ion battery quality assurance—produces a complex and hazardous liquid waste stream.

Treating this wastewater was not only crucial for regulatory compliance, but also essential to maintaining production continuity and protecting the company’s environmental and brand commitments. For the manufacturer, wastewater treatment is a strategic priority, directly impacting production capacity, supporting corporate sustainability objectives, and reinforcing its leadership position in the highly competitive EV battery market.

CHALLENGE

This project represents the manufacturer’s third high-capacity wastewater treatment system to support increased production output. The facility needed a solution capable of:

• Treating a complex inorganic, high-pressure wastewater stream
• Supporting rapid production growth
• Aligning with corporate sustainability and water reuse goals
• Ensuring reliable, long-term operation under industrial conditions

Having previously delivered a successful solution at a large U.S. gigafactory in Sparks, Nevada, Newterra was the natural choice to meet these technical and operational challenges.

SOLUTION

Newterra was sole-sourced for the Midwest project due to its demonstrated expertise in high-pressure, inorganic wastewater streams generated by advanced battery manufacturing.

Key components of the solution include:

• Custom-engineered deionization (DI) system
• High-pressure liquid-phase treatment vessels, featuring Cansorb® P technology to manage the facility’s specific chemical profile and loading
• Engineering, design, and manufacturing at Newterra’s San Luis Obispo, California facility
• Full integration of water reuse capabilities to support sustainability goals

The result is a robust, efficient, and scalable treatment system that supports the manufacturer’s growing production demands while mitigating regulatory risk and advancing water reuse initiatives.

RESULTS

Newterra’s advanced wastewater treatment technologies provide EV battery manufacturers with a suite of operational and environmental benefits. By enabling reliable high-volume treatment, facilities can maintain uninterrupted production while converting hazardous waste into reusable process water, supporting environmental stewardship. These systems ensure full regulatory compliance, reduce freshwater demand, lower operational costs through internal water recycling, and offer scalable solutions that strengthen regional infrastructure and accommodate future facility growth.

The overall results were as follows:

• Reliable high-volume wastewater treatment enabling uninterrupted production
• Enhanced environmental stewardship by converting hazardous waste into reusable process water
• Regulatory compliance with local and federal discharge requirements
• Reduced freshwater demand and lower operational costs through internal water recycling
• Supports regional infrastructure and demonstrates scalability for future EV battery facilities

The project reinforces the long-standing partnership between Newterra and the manufacturer, built on proven performance, technical expertise, and shared commitment to sustainability.

Sustainable Wastewater Reuse Solutions for the Growing EV Battery Industry

As of early 2025, the U.S. EV battery industry is experiencing rapid expansion, with ten large-scale plants under construction and more than 34 sites planned, operational, or in development nationwide. This growth underscores the critical importance of effective wastewater treatment to protect local waterways, maintain regulatory compliance, and support high-volume battery production. Advanced technologies, such as Newterra’s wastewater treatment systems, play a key role in addressing these challenges, providing reliable, scalable, and environmentally responsible solutions for the rapidly expanding EV battery sector.