THE RIGHT CHOICE OF STANDBY BATTERY FOR CRITICAL APPLICATIONS

- MD ABDUL RAHEMAN

STORAGE BATTERY
A DEVICE THAT STORES ELECTRICAL ENERGY IN SOME OTHER FORM TO REPRODUCE WHENEVER AND WHEREVER REQUIRED
EITHER DUE TO SUDDEN DISRUPTION OF A.C MAINS POWER OR DUE TO COMPLETE UNAVAILABILITY OF MAINS POWER DURING USAGE AS IN PORTABLE APPLICATION THIS CLEARLY DEFINES TWO REGIMES OF APPLICATION UPS, INVERTERS, TELEPHONE EXCHANGES, POWER STATIONS, SWITCHING CELL PHONES, TOYS, FORK LIFTS, ELECTRIC VEHICLES, SOLAR PHOTOVOLTAICS

STANDBY APPLICATION

CYCLIC APPLICATION

BATTERY SYSTEMS WORLDWIDE

LEAD ACID

NICKEL CADMIUM

NICKEL METAL HYDRIDE

LITHIUM ION

FUEL CELL
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APPLICATION POPULARITY
INDUSTRIAL STANDBY POWER

LEAD ACID
NICKEL CADMIUM LITHIUM ION

PORTABLE POWER

NICKEL METAL HYDRIDE

NICKEL CADMIUM

HIGH END APPLICATION TORPEDOES, SPACE NICHE POWER GENERATION

SILVER - ZINC

FUEL CELLS
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ADVANTAGE LEAD - ACID

LOW COST
ABUNDANT MATERIAL APPLICATION VERSATILITY

WELL DEVELOPED SERVICING & RECYCLING INFRASTRUCTURE

BASIC ELECTROCHEMISTRY

LEAD ACID

ANY ELECTROCHEMICAL CELL COMPRISES OF TWO INDEPENDENT HALF CELLS

POSITIVE ELECTRODE ON DISCHARGE Pb++++ + 2e- Pb++ (PbO2 PbS04) A REDUCTION REACTION ABSORBING ELECTRON NEGATIVE ELECTRODE ON DISCHARGE Pb0 Pb++ + 2e(Pb PbSO4) AN OXIDATION REACTION RELEASING ELECTRON
CHARGED DISCHARGED

PbO2 + Pb + 2H2SO4
POS. NEG.

PbSO4 + PbSO4 + 2H2O

POS. NEG.
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BASIC ELECTROCHEMISTRY
CHARGED

NI - CD

DISCHARGED

2NiOOH + 2H2O + Cd
NEG.
POS

2Ni(OH)2 + Cd(OH)2
NEG. POS

KOH IS PRESENT AS ELECTROLYTE, IN VERY DILUTE FORM, WHICH ESSENTIALLY FUNCTIONS AS ION CONDUCTOR. ALTHOUGH WATER GETS CONSUMED ON DISCHARGE, THE CHANGE IN CONCENTRATION OF THE DILUTE SOLUTION IS MINIMAL, AND HENCE CANNOT BE USED AS AN INDICATOR OF STATE OF CHARGE.

LEAD ACID BATTERY

CATEGORISATION

CELL WITH FREE ELECTROLYTE

FLOODED or CONVENTIONAL

VALVE REGULATED LEAD ACID (VRLA)

CELL WITH IMMOBILISED ELECTROLYTE

LEAD ACID BATTERY. AN OVERVIEW

LEAD-ACID BATTERY IN ITS CONVENTIONAL PRISMATIC DESIGN PRESENTS THE POSITIVE AND NEGATIVE ACTIVE MATERIAL TO THE ELECTROLYTE IN THE SHAPE OF POSITIVE & NEGATIVE PLATES.

PLATES ARE CONSTITUTED OF

ACTIVE MATERIAL SUPPORT STRUCTURE

LEAD ACID BATTERY. AN OVERVIEW

THE SUPPORT STRUCTURE HAS THE DUAL FUNCTION OF :

PROVIDING THE FIRM MECHANICAL SUPPORT TO THE ACTIVE MATERIAL

CONDUCTING ELECTRICITY FROM THE LUG TO THE ENTIRE MASS OF ACTIVE MATERIAL OR VICE CERSA
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LEAD ACID BATTERY. AN OVERVIEW

EFFICIENCY OF PERFORMANCE OF A PRODUCT IS LARGELY DEPENDENT ON THE STRUCTURE AND GEOMETRY OF A POSITIVE PLATE.
THE TYPE OF BATTERY IS DENOTED AS PER THE GEOMETRY OF THE SUPPORT STRUCTURE OF THE POSITIVE PLATE. THE FOLLOWING TYPES ARE PREDOMINANT : (A) (B) FLAT TUBULAR

(C)

PLANTE

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The Lead-Acid Technology

Technology Wise Categorisation
Industrial Lead Acid Battery

FLOODED

VRLA

FLAT

TUBULAR

PLANTE

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WHAT IS FLAT PLATE ?

MORPHOLOGY

WIRE-MESH LIKE SUPPORT STRUCTURE - GRID

ACTIVE MATERIAL PASTED ON GRID - EXTERNALLY

A CHEMICAL BONDING HOLDS THE ACTIVE MATERIAL IN PLACE THROUGHOUT THE SERVICE LIFE
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WHY FLAT PLATE ?

ADVANTAGES

1. MINIMUM LEAD MOST ECONOMICAL & HIGHEST ENERGY DENSITY 2. LARGE ACTIVE SURFACE AREA EXCELLENT HRD AND CHARGE ACCEPTANCE
3. MOST SUITABLE FOR HIGH CURRENT, SHORT DURATION APPLICATION viz. SLI, INVERTER ETC.

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WHY NOT ?

LIMITATIONS

1. ACTIVE MATERIAL SHEDDING LIMITED CYCLING CAPABILITY 2. VULNERABLE TO BOTH UNDERCHARGE & OVERCHARGE 3. SEVERELY AFFECTED BY PROLONGED HIGH TEMPERATURE OPERATION

LIMITED USAGE IN INDUSTRIAL APPLICATIONS

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WHAT IS TUBULAR ?

MORPHOLOGY

GAUNTLET + BOTTOM BAR + LEAD TOP BAR

RETAINS THE ACTIVE MATERIAL

LEAD TOP BAR

ACTIVE MATERIAL

SPINE

GAUNTLET
PLASTIC BOTTOM BAR
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WHY TUBULAR ?

FEATURES

NO ACTIVE MATERIAL SHEDDING LOW SPINE CORROSION

LOOSE PACKING OF ACTIVE MATERIAL

EXTENDED SERVICE - LIFE

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WHY TUBULAR ?

ADVANTAGES

BEST SUITED FOR CYCLING

RESISTANT TO OVER-CHARGE RECOVERY FROM DEEP DISCHARGE PSOC OPERATION

EXTREME TEMPERATURE OPERATION LOW MAINTENANCE WITH PROPER ALLOY

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WHY NOT ?

LIMITATIONS

1. MODEST HIGH RATE DISCHARGE PERFORMANCE. 2. LOSES CAPACITY AS BATTERY AGES

3. REQUIRES PERIODIC EQUALIZING AND/OR BOOST CHARGING

4. REQUIRES PERIODIC TOPPING UP 5. ANTIMONY POISONING LEADS TO SLOWLY DECLINING VOLTAGE PROFILE AND INCREASING WATER LOSS AS THE BATTERY AGES.

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Plante

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WHAT IS PLANTE ?

MORPHOLOGY

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WHAT IS PLANTE ?

MORPHOLOGY

CAST OF 99.99% PURE LEAD LAMELLAR GRID

STRUCTURE ENHANCED ACTIVE SURFACE AREA

INTEGRAL GRID
ACTIVE MATERIAL
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WHY PLANTE ?
LAMELLAR GRID DESIGN

UNIQUENESS
HIGH SURFACE AREA IMPROVED HIGH RATE DISCHARGE AND CHARGE ACCEPTANCE THIN FILM OF ACTIVE MATERIAL LOW INTERNAL RESISTANCE NO ALLOYING ELEMENT NO LEACHABLE IMPURITY. THUS NO POISONING EFFECT AND VOLTAGE PROFILE AND WATER LOSS REMAINS FAIRLY CONSTANT VERY LOW GASSING DRASTIC IMPROVEMENT OF TOPPING UP REQUIREMENT HIGHEST CELL POTENTIAL LOW EQUILIBRIUM FLOAT CURRENT

ULTRA PURE 99.99% LEAD

INTEGRAL GRID ACTIVE MATERIAL

CONTINUOUS ACTIVE MATERIAL REGENERATION

NO LOSS IN CAPACITY IN LIFE

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PLANTE

NO LOSS IN CAPACITY

CONTINUOUS REGENERATION OF ACTIVE MATERIAL

TOTAL LEAD-DI-OXIDE CONTENT FAIRLY CONSTANT THROUGHOUT THE LIFE SPAN INDICATING A CONSTANT CAPACITY OUTPUT

CAPACITY DEGRADATION OVER LIFE

TUBULAR : 20%

AGEING FACTOR
1.25

VRLA
Ni-Cd

:
:

20%
20%

1.25
1.25

PLANTE

ZERO

1.00

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PLANTE
HIGH SURFACE AREA

FAST RECHARGE

HIGH CHARGING RATES POSSIBLE. CHARGING AT 0.25 C10 AMPS UPTO 2.4 VOLTS PER CELL WITHOUT PROBLEM

NO ANTIMONY POISONING HIGH FLOAT POTENTIAL POSSIBLE.

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PLANTE

LONG LIFE

VERY THICK POSITIVE ENOUGH CUSHION

AGAINST CORROSSION

LOW SUSCEPTIBILITY TO OVERCHARGE

DUE TO VERY LOW EQUILIBRIUM FLOAT CURRENT OF THE ORDER OF 1 mA/AH UNDER NORMAL FLOAT CONDITION

LOW FLOAT CURRENT AND HIGH PURITY OF

LEAD LOWERS THE CORROSSION RATE

LIFE EXPECTANCY OF AROUND 15 YEARS PLUS.

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PLANTE

EASY MONITORING

TRANSPARENT SAN (STYRENE ACRYLONITRILE) CONTAINER EASY VISUAL MONITORING OF CELL INSIDE

ANY ODD BEHAVIOUR CAN BE MONITORED AND CORRECTED MUCH BEFORE IT SHOWS UP AS A FAILURE MODE

EASY CLEANING OF CELLS FROM UNAVODABLE SLUDGE DEPOSITION TO AVOID SHORT CIRCUIT AND RELATED TROUBLES

RELIABILITY - REITERATED
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WHAT IS VRLA ?

SEALED CAN BE KEPT IN ANY ORIENTATION.

NO TOPPING-UP REQUIRED EVER MAINTENANCE-FREE. A ZERO EMISSION PRODUCT. BATTERY COMES CHARGED.
COMPACT.

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The Oxygen Recombination Cycle

FLOODED SYSTEM eeVR LA SYSTEM

O2
+

Charger
i

H+

H2
+

Charger
i

O2
H+ H+

2Pb + O2= 2PbO

PbO + H2SO4 = PbSO4 + H2O

PbSO4 + 2e- + 2H+ = Pb + H2SO4

H+

O2
ELECTROLYTE - H2SO4

ABSORPTIVE SEPERATOR - ELECTROLYTE

MECHANISM DURING CHARGING

At +ve Electrode H2O=1/2O2 + 2H+ +2eAt -ve Electrode
2Pb + O2= 2PbO (Exothermic Reaction) PbO + H2SO4 = PbSO4 + H2O (Exothermic Reaction) PbSO4 + 2e- + 2H+ = Pb + H2SO4 (Electrochemical Reaction)

RECOMBINATION MECHANISM OF VRLA CELLS WITH MICRO GLASS SEPERATORS IN COMPARISON WITH FLOODED CELLS

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ADVANTAGES OF VRLA

1. NO TOPPING UP EVER
2. COMPACT OCCUPIES LOW FOOT PRINT

3. NO CORROSSIVE EMISSION 4. EXCELLENT HIGH DISCHARGE PERFORMANCE

5. EXCELLENT CHARGE ACCEPTANCE 6. SUPPLIED FACTORY CHARGED

7. SUITABLE FOR FLOAT AND MODERATE CYCLIC DUTY

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Venting Arrangement Of A VRLA Battery

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LIMITATIONS OF VRLA
1. EXTREMELY SENSITIVE TO CHARGING ABUSE

2. HIGH TEMPERATURE OPERATION RISKY FOR LIFE. CORROSION DOUBLES PER 100 C RISE. DRYING OUT ENHANCED IN HIGH TEMPERATURE OPERATION
3. NOT SUITED FOR DEEP DISCHARGE RECHARGE CYCLIC OPERATION

4. COMPARED TO TUBULAR, INFERIOR IN PARTIAL STATE OF CHARGE OPERATION

5. ASSESSMENT OF STATE-OF-CHARGE AND STATEOF-HEALTH DIFFICULT
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SIZING FACTORS

PARAMETERS

PRIMARY

LOAD CURRENT LOAD DURATION NOMINAL SYSTEM VOLTAGE MINIMUM SYSTEM VOLTAGE

MINIMUM OPERATING TEMPERATURE DESIGN MARGIN AGEING FACTOR

SECONDARY

FACTORS SPECIFIC TO APPLICATION

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SIZING FACTORS

FREQUENCY OF DISCHARGE
DEPTH OF DISCHARGE

OTHER FACTORS

APPLICATION CRITICALITY CHARGING CONSTRAINT MAINTENANCE CONSTRAINT

THEY WOULD DECIDE THE RIGHT DESIGN AND TECHNOLOGY USAGE AND WOULD PRECEDE THE SIZING EXERCISE

OPERATING AMBIENT TEMPERATURE

SPACE CONSTRAINT
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STORAGE SOLUTIONS

SELECTION LOGIC

POWER PLANT SUPERCRITICAL OPERATION PLANTE MAJOR PROBLEM IN TOPPING UP LM TUBULAR OR VRLA RESTRICTION IN SPACE AVAILABILITY VRLA

HIGH OPERATING TEMPERATURE TUBULAR

FREQUENT CHARGE DISCHARGE CYCLE TUBULAR PSOC OPERATION TUBULAR

WIDELY VARYING TEMPERATURE ENVIRONMENT TUBULAR

VERY LOW TEMPERATURE OPERATION VRLA CORROSIVE AND EXPLOSIVE ENVIRONMENT VRLA

QUICK RECHARGE TUBULAR FREQUENT DEEP DISCHARGE WITH HIGH TEMP. TUBULAR
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Thank you

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