PROCEDURE FOR BATTERY REPOWERING WITH BATCURE
Before you carry out BATCURE treatment on batteries that have lost power storage capacity, it is important to know the present health condition of the battery that is being subjected to BATCURE treatment.
CHECKING BATTERY VOLTS:
Note the battery volts first. For automotive 12V batteries the minimum volts should be above 10.5Volts and for 6V battery it should be above 5.25Volts.These parameters for automotive batteries are valid for a battery that has been removed from service within in 30 days. If the batteries are removed from service for more than 30 days then the volts may be on lower side, such batteries be charged for 2 to 3 hours and then disconnected from charging machine. Allowed to settle down for 12 hours and then measure the volts. If the volts are above the minimum requirement as mentioned above, the battery is selected for further investigations. For traction battery the minimum volts should be 1.75 per cell.
CHECKING THE SPECIFIC GRAVITY:
Note the specific gravity in each cell with hydrometer. You may find different gravity in different cells. However, heavily sulfated cells will show exceptionally low gravity as compared to other cells. Mark the low gravity cells.
CHECKING THE MECHANICAL FAULTS:
It is the most difficult job to find a mechanical damage to a particular cell or cells. However, on the basis of our experience we have tried to enlist some important steps that can help you to find a mechanically damaged cell.
After you have noted the battery volts and specific gravity in each cell, connect the battery to a charging machine. Apply normal current charging that you use for different capacity batteries, normally it should be 8 to 10% of battery rated capacity. Carry out battery charging for 3 hours. After 3 hours observe the following while battery is still being charged.
(1) Is there a uniform bubbling or gassing reaction in each cell?
(2)Is there any one or more cells giving high bubbles as compared to other cells?
(3)Is there an exceptional rise in battery electrolyte temperature that is giving high bubbling?
(4)Is the current passing in each cell? If there is no bubbling at all in a particular cell or cells then that cell has a permanent mechanical failure.
If all the cells are giving uniform reaction and normal gassing is observed then the battery has a better chance of fixing with BATCURE.
If one or more cells are giving exceptionally high bubbles or gassing then it is possible that such cells have heavy shedding of active materials, separator puncture, mechanical short, or sludge formation at the bottom area. Such cells will not give any improvement in the gravity and will remain same as it was before battery was put to charge. Such batteries are discarded.
Most batteries that have been sulfated will give a rise in electrolyte temperature but will not have uneven gassing in all the cells such batteries can be preferred for BATCURE treatment.
If you find that one or more cells do not give any bubbling at all then it confirms that the current is not passing through that cell or cells. This may be due to inter cell welding damage. Such batteries are also discarded.
After you have made above analysis, remove the battery from charging machine. Let it come to room temperature and then measure the battery volts and gravity in each cell. Compare the volts and gravity reading with that taken before the battery was put to charging machine for 3 hours.
If you find that there is an improvement in battery volts and gravity in each cell, such batteries is selected for BATCURE treatment.
Another simple method of finding the battery sulfation is to find out the power storage capacity left in the battery. Suppose your healthy battery gives 6 hours of power at a particular discharge current but due to sulfation it has now come down to 1 hour only. That means battery has lost 5 hours power storage capacity due to sulfation. Since the battery has still one hour power storage capacity, it confirms that there is no mechanical damage and battery can be treated with BATCURE.
ADDITION OF BATCURE IN A SULFATED BATTERY:
HOW MUCH BATCURE IS REQUIRED PER CELL?
In order to find out how much BATCURE be added per cell of a battery, please find out the volume of electrolyte in each cell of the battery. This can be found from battery manufacturer technical specifications for a particular battery. If the electrolyte quantity is given in kilos (weight) per cell, then divide the weight by 1.3 (S.G) for traction and VRLA sealed battery and by 1.25(S.G.) for liquid automotive battery to find the volume of electrolyte in liters.
Once you know the volume of electrolyte in liters per cell, add 5 ml BATCURE per liter. Suppose there is a 5 liter electrolyte in each cell then you will be required to add 25 ml BATCURE per cell. Use doctor syringe to measure out BATCURE from the bottle and inject it directly in each cell.
After addition of BATCURE mix it well with electrolyte using hydrometer. Reddish yellow color will be there in electrolyte. Leave the battery in idle condition till the electrolyte becomes colorless. This may take 12 to 24 hours. The less sulfated healthy cells will have faster discoloration and more sulfated cells will have slower discoloration. If the cells are mechanically damaged then there will not be discoloration.
CHARGEING A BATTERY:
After the discoloration of electrolyte has been completed, carry out normal battery charging using different amps for different ah capacity batteries. Continue to charge the battery till full gravity is observed in each cell and the battery volts reached above 15.5V for a 12V battery and 7.5V for a 6Volts battery. For traction battery is should be 2.6volts per cell. For example for 36volts battery it should be 2.6volts X 18 cells= 46.8 volts minimum. These are online volts while battery is on charging machine.Fully charged battery is then removed from charging machine and allowed to settle to room temperature. When the battery has cooled to room temperature, note the volts and gravity in each cell. You will find that the battery is showing more then nominal volts of battery. All the cells will show at least 1.200 specific gravity in each cell.
DISCHARGING THE BATTERY:
A charged battery is required to be discharged for sulfation removal. Discharge can be carried out using standard discharge testers or dc halogen bulbs. Complete discharge is recommended. Recharge the battery/discharge the recharged battery for at least 3 to 4 times for complete removal of sulfation.
LOAD TEST OF A BATTERY:
After the battery has been cycled for charge/discharge, carry out a load test as per standard load testing procedure. We strongly recommend that once you find during the course of battery operations that battery has gradually started to loss power storage capacity, you must immediately add BATCURE to each cell to longer the life of the battery because once the battery begins to loss its power storage capacity and if not treated with BATCURE there will be a faster sulfation and more corrosion of positive plates resulting in a permanent damage to the battery.
We also strongly recommend that you must add BATCURE in your healthy batteries as well so that you can protect the batteries from sulfation and corrosion. There is no battery in the world without sulfation since it is a part of battery electrochemistry and therefore you must add BATCURE in each and every battery.
VRLA BATTERY REPOWERING WITH BATCURE
In the case of VRLA batteries, you will find a plastic strip on the top of the battery case. First remove this strip with the help of a screw driver or a knife. Once you remove the strip, you will find that there are 3 or 6 (3 for 6Volts and 6 for 12Volts) small vents which are covered with a rubber cap. Remove the rubber caps from all vents. Then add required quantity of BATCURE in each cell. (Quantity of BATCURE required depends on the size of the battery, add 5 ml BATCURE per cell for 20 ah to 50 ah, 7 ml per cell for 55 ah to 80 ah, 8 ml per cell for 88 to 120 ah, 10 ml for 130 ah to 150 ah, and 12 ml per cell for 160 to 200 ah capacity battery)
After addition of BATCURE add distilled water up to plate height in each cell. After water has been added, shake the battery to and fro for few times for uniform mixing and then leave the battery for 24 hours in idle condition during this time BATCURE will go to battery plates.
After 24- hours carry out normal charging of the battery. A fully charged battery is then discharged. Repeat 3 to 4 charge -discharge cycles to remove the sulfation completely.Once the battery has come to required level of capacity, close the vents with rubber caps and reseal the top with the strip using suitable adhesive.
We strongly recommend that all new batteries or in-service batteries be treated with BATCURE to inhibit sulfation for longer sulfation free battery life. Add only half the quantity of BATCURE that was used for sulfated batteries. For new or in-service batteries no cycling is required. Add BATCURE once in year to keep your batteries healthy.
We have found that many people use higher than recommended amperes or charge the battery for longer time then required to charge the battery when they find that battery capacity has been going down. We strongly advise not to do so because this practice will further damage the battery.
We have also found that many people use fast chargers to save the battery charging time, we strongly advise not to use fast chargers since it will increase the internal temperature and water loss from the battery. Fast charging could also damage the positive plates.
We welcome your questions and suggestions to improve the way we use batteries.
For more information, please write to,
405, ABHISHEK COMPLEX,
SECTOR-11, GANDHINAGAR-382011, INDIA.
NEGATIVE PASTE ADDITION AND DRY CHARGED PLATES
BATCURE is the only additive for battery manufacturing process that gives visible difference in the life and performance of all types of lead acid batteries. No additive makes as difference as BATCURE because it has been tested by leading battery manufacturers for its performance. BATCURE is multi utility product that is used in negative plate paste to increase efficiency, prevention of aerial oxidation of freshly formed negative plates as well as for removal of sulfation to restore lost power storage capacity.
NO SINGLE ADDITIVE OFFERS AS MANY ADVANTAGES AS BATCURE.
(SULFATION INHIBITOR, SULFATION REMOVER, ELECTROLYSIS RETARDER AND AERIAL OXIDATION INHIBITOR)
There is no battery in the world that is 100% free from sulfation; this is because the battery chemistry uses sulfuric acid in paste manufacturing and as an electrolyte. Sulfation is considered to be the number one cause for partial or complete failure of the battery performance. Sulfation is observed in all types/size of batteries, that is WET, FLOODED, VRLA SEALED OR GELLED batteries. In order to save the batteries from sulfation it is important to manufacture battery plates that are most resistant to sulfation.
HOW BATCURE WORKS AND IMPROVES THE QUALITY OF NEGATIVE PLATES?
Lead oxide is used in conventional lead battery manufacturing process. Since lead oxide contains 25 to 30% free lead (not converted to lead oxide), it is necessary to convert free lead into active material. In order to convert free lead into an active material sulphuric acid is added to lead oxide while preparing a paste for positive and negative plate. Conversion of free lead into active material (lead sulfate) is an important reaction/process.
In order to ensure that all the free lead is converted to lead sulfate without damaging lead oxide, paste manufacturing technology plays an important role. Conversion of free lead into lead sulfate demands specific process control, drying, and curing of pasted plates. Quantity and SG of electrolyte to be added for paste manufacturing depends on percentage of FREE LEAD and particle size. Conventionally, it takes 6 to 7 days for all the free lead to convert to lead sulfate during curing and drying. The maximum permissible free lead must be less than 1% after curing and drying.
Conversion of free lead to lead sulfate results in increase of active material of paste. Therefore, at the end of curing and drying process, there are two major chemicals, Lead oxide and Lead Sulfate in the grid paste. However, both these chemicals are electrically non conductors. Secondly, the presence of lead sulfate as active material reduces the charge acceptance when plates are formed. It is, therefore, very important to ensure that both these chemicals are formed in a such a way that they have better charge acceptance for higher volts generation on positive and negative plates.
Addition of BATCURE in paste manufacturing process ensures that lead sulfate so formed in the paste zone after drying/curing process has faster and better charge acceptance and builds higher negative volts. Addition of BATCURE also ensures that Lead Oxide is not excessively damaged due to exothermic reaction that takes place while adding sulfuric acid in paste preparation. BATCURE controls and minimizes the formation of tetra basic lead sulfate and allows only tri basic sulfate to form.
Addition of BATCURE to negative plates gives higher negative volts (-0.25 to -0.30 volts) at the end of formation measured with Cadmium Rod Test. Paste prepared without addition of BATCURE gives lower negative plate volts (-0.18 to -0.20 volts).Lower negative plate volts means lower battery capacity, higher self discharge and pre mature capacity loss due to sulfation).
HOW TO USE BATCURE IN PLATE MANUFACTURING PROCESS?
BATCURE is strongly recommended for manufacture of negative plate paste process. We recommend 1 ml BATCURE per kilo of Lead Oxide as negative paste additive for automotive batteries and 2 ml BATCURE for thick plate standby and tubular batteries. To add BATCURE in negative paste making process, prepare a BATCURE solution in D.M water to be added in the powder mix.
For example, if you have a negative paste making batch of 50 kgs, you will require 50 ml BATCURE for automotive battery plates. Take about 6 liter DM water and add 50 ml BATCURE in it. Mix it well. Add this solution in the negative powder mix and start mixing process. Run the mixer for 20 minutes at least for uniform mixing. Then start slowly addition of required quantity of acid to prepare a negative paste.
For thick plate/tubular negative plates add 100 ml BATCURE in 6 liter DM water for 50 kgs lead oxide powder.(Please consult us about quantity of other additives, acid SG and quantity, water, etc. to be used for negative paste making).
HOW TO PREVENT AERIAL OXIDATION OF NEGATIVE PLATES?
During formation process, the negative plates are converted to spongy pure lead, freed from sulfate and oxygen. It means negative plates are completely in a reduction stage. However, when these plates are removed from formation containers for washing and drying, these plates come in contact of atmospheric oxygen. Since negative plates are in highly reduced state (-0.25 volts), means oxygen deficient, they immediately begin to react with oxygen in the air and start absorbing oxygen. Absorption of oxygen by freshly formed negative plates is an exothermic reaction. This is also known as aerial oxidation of freshly formed negative plates. Absorption of oxygen at high temperature by negative plates results in the reformation of lead oxide (spongy Pb + oxygen). The lead oxide so formed is hard to convert to pure spongy lead again and leads to lower battery capacity. Aerial oxidation of freshly formed negative plates also reduces negative plate volts.
Your efforts (time, labor, electricity, etc) for removing oxygen and sulfate by formation are lost if the negative plates are not properly protected from AERIAL OXIDATION.
PROTECTION OF FRESHLY FORMED NEGATIVE PLATES IS MOST ESSENTIAL PART OF A QUALITY BATTERY PLATES MANUFACTURING AND MUST NOT BE IGNORED.
PROCEDURE FOR PROTECTION OF FRESHLY FORMED NEGATIVE PLATES WITH BATCURE:
Prepare a water bath in plastic tank near your formation line. To prepare a bath add 15 ml BATCURE per liter of water. For example to prepare 1000 liter bath for negative plates dipping, add 15 liter BATCURE to 1000 liter water.
After formation is completed wait for at least 1 hour before you start dismantling of plates. Dismantled negative plates are IMMEDIATELY transferred in to a bucket having DM water. After sufficient numbers of negative plates are stocked in the bucket, take the bucket to dipping bath and immerse negative plates in the bath immediately. Leave the negative plates in the bath for minimum 36 hours. Do not wash negative plates before or after dipping and soaking. Take out the plates from bath after 36 hours and directly allow drying in a less ventilated room at room temperature. DO NOT DRY IN SUN LIGHT OR UNDER THE FAN.
To maintain BATCURE concentration in bath, add 50 ml BATCURE after 1000 nos. standard size plates are immersed. New bath is recommended after 6 months.
For more details:
405, ABHISHEK CENTER, SECTOR-11,
(SYNTHETIC POLYMER GEL ELECTROLYTE)
WHAT IS ELECTROGEL?
ELECTROGEL is a viscous synthetic polymer gel electrolyte
FREE from SILICA. It is soluble in water, acid and other
ionic solvents. It is manufactured using specialty chemicals
and proprietary process for the first time. ELECTROGEL is
a revolutionary product for the battery industry. It is
non-corrosive, stable, odor free, non-hazardous,
WHY ELECTROGEL FOR BATTERIES?
The two major problems associated with lead acid batteries
are CORROSION and SULPHATION. Unless and until
non-corrosive electrolyte is developed for the batteries or
the acid’s corrosive properties eliminated, these two problems
continue to limit the life and performance of the batteries. It
is therefore very important to minimize the damaging role of
sulphuric acid as an electrolyte for the batteries.
ELECTROGEL is developed to meet the challenges posed by
highly corrosive sulphuric acid for battery. ELECTROGEL
converts more than 98% liquid acid into immobile solid
permanent polymer electrolyte.
ELECTROGEL offers following major advantages
(1)PROTECTS POSITIVE PLATES FROM CORROSION.
(2)PROTECTS NEGATIVE PLATES FROM SULPHATION.
(3)PROTECTS PLATES FROM EXTERNAL AND
(4)PROTECTS ACTIVE MATERIALS FROM SHEDDING.
(5)VERY LOW WATER LOSS.
(6)PROTECTION AGAINST DEEP DISCHARGES.
(7)LONG LIFE BATTERY.
(8)ENVIRONMENT FRIENDLY BATTERY.
(9)ALL WEATHER BATTERY.
(10)BATTERIES CAN BE MANUFACTURES DIRECTLY
FROM GREEN PLATES.
HOW ELECTROGEL PREVENTS CORROSION AND
ELECTROGEL when filled into the new battery along with
sulphuric acid utilizes the power from the charged plates and
turns into a viscous gel within 3 to 4 hours (in the case of
formed plate batteries) depending on the size of the battery.
On charging the battery, the viscous gel slowly turns into a
compact protective film on each battery plate. The protective
film so formed prevents direct attack of sulphate ions on the
battery grids. The compact film also helps to check the
volumetric expansion/contraction of active materials during
charge/discharge process thereby shedding of active materials
is prevented. Migration of corrosion by products from positive
plates to negative plates is eliminated by the film.
The protective film also checks the heat generation during
charge/discharge process. Dynamic and static sulphation are
best prevented by the film, as after film formation negative
plates active materials remain free from contamination.
PREVENTION OF ACTIVE MATERIAL SHEDDING FROM
POSITIVE PALTES DURING BATTERY MANUFACTURING:
Formed positive plates tend to shed active materials even
during battery manufacturing. The lead peroxide formed
after formation charges have no chemical bonding but only a
physical bonding. Any bonding additives that are added into
paste making also get oxidized and offer no bonding properties
to the final product on positive plates. This results in the
shedding of lead peroxide during plates handing in the plant
as well as when batteries are manufactured. Shedding of lead
peroxide also increases the fine dust in the plant and is
hazardous to the working conditions. The dark black material
(lead peroxide) also sticks to hands and body of the workers.
To eliminate this problem dried +ve plates are applied with
10% ELECTROGEL solution in water either by soaking or by
brush application. The +ve plates after ELECTROGEL
application are dried at room temperature, the fine adhesive
film will form on +ve plate active materials, which will
the shedding of active materials during battery manufacturing. The
ELECTROGEL solution forms a net like structure in the
entire active material of positive plates and holds the active
materials together and prevents it from shedding.
HOW MUCH EXTRA LIFE ELECTROGEL GIVES?
Our field and laboratory trials have shown that ELECTROGEL
almost gives more than double the life. Depending upon battery
manufacturing technology, still better results are expected.
CAN ELECTROGEL BE USED FOR ALL TYPES OF
LEAD ACID BATTERIES?
ELECTROGEL can be used for all types of lead acid
batteries. Either tubular or flat plates, ELECTROGEL
helps to enhance the life of the battery.
HOW TO USE ELECTROGEL IN BATTERY?
FOR GREEN PLATE BATTERIES:
Prepare a mixture of ELECTROGEL and sulphuric acid
(20% ELECTROGEL+ 80%SULPHURIC ACID of 1350 S.G for
automotive battery and 1400 S.G. for industrial battery). Final S.G. of
mixture will be 1260 for automotive battery and 1280 for
industrial battery. ELECTROGEL and acid must be thoroughly
The batteries are assembled using GREEN PLATES. The
mixture is then filled into each cell up to plate height. Leave the
battery for 12 hours in idle condition. After 12 hours, carry
out normal charging of the battery, preferably with 7 to 8%
current of the battery rated capacity. As the charging of the
battery progresses, the liquid mixture begins to turn into a
viscous polymer. At the same time the plates also get charged. Further charging converts viscous material into a solid protective film on each plate and covers the entire cell. Plates also get charged up and voltage development takes place.
Charging should be continued till you find that online volts
reaches 16.5 volts for a 12 volts batteries, for 6 volts it
will be 9.5 volts and for 2 volts cell, it will be 3.5 volts.
At the end of charge there will not be any free liquid in the
cell, except a small quantity of free liquid at the bottom of
each cell. Most liquid that was filled initially will get
converted into a polymer film formation. Most acid will become
the part of the polymer film and will remain in the film
permanently. The conversion of liquid mixture into solid
polymer film at the end of full activation creates more space
in to each cell. To fill up the space add again acid+gel
mixture above plate height. Let the new addition of mixture
to settle down in each cell. This may take 15 to 30 minutes.
Fully activated battery is completely discharged with DC bulbs
or standard discharge tester. Discharged battery is again
recharged till online open circuit volts reach up to 16 volts
of a 12volts battery.
Charge/discharge cycles be performed at least three times and
every time each cell should be filled with acid+gel mixture.
ADVANTAGES OF GREEN PLATE BATTERY
MANUFACTURING USING ELECTROGEL:
(1) ELECTROGEL technology allows manufacturing batteries
directly from green plates. This technology eliminates the
formation of plates separately. As the plate formation process is
eliminated, the plant remains free from acidic fumes. No need
to assemble plates for formation which saves substantial time
and labor. No need to monitor or adjust electrolyte gravity
every time you carry out new batch. No shedding of active
materials during formation stage, no mud formation at the
bottom of the formation jars, which saves costly lead oxide
and acid. No need to monitor charging equipments. No need to
wash the plates after formation is completed which saves lots
of water from being polluted. No need to protect –ve plates
from aerial oxidation (dry charge process).Over and above the
most important advantage is saving of electricity cost.
Container formed battery plates required to be recharged again.
ELECTROGEL technology is suitable for all types and all
size lead acid batteries manufactured from green plates.
VRLA sealed batteries suffer from two major disadvantages.
(1)Since these batteries are filled with high gravity low
volume acid (starved acid), the liquid dries out rapidly
resulting in the premature failure of the batteries.
(2)Due to stratification in the VRLA batteries, the
different gravity zones develop in the AGM separators,
resulting in the faster sulfation build up.
ELECTROGEL technology will eliminate both these problems
since most acid will remain in the solid polymer film.
(2)ELECTROGEL for a formed /dry charged plate’s battery:
Filling of ELECTROGEL + ACID mixture (20% v/v/ of
ELECTROGEL+ 80% v/v/ of acid) into a new battery having
formed plates should be done carefully to avoid excessive heat and gas
generation. We strongly recommend batteries having formed
plated when to be filled with mixture must be immersed
into cold water bath up to plate height(filling of mixture
into a battery having formed plates generates lot of heat and
gas instantly). Water bath temperature must be 20 to 25 degree
centigrade or less. Fill the mixture up to plate height only.
Leave the batteries into water bath for 3 hours to cool down.
Take out the batteries from water bath after 3 hours and leave
them outside for further cooling for another 6 to 9 hours. If
topping up is required, add mixture to cover unto plate
height. (If water bath is not used then gel mixture will
flow out of battery due to rapid polymerization.)
Cooled batteries are then put to charging using either
constant current or constant voltage charger. Normal charging
procedure is followed. During charging process if topping up
is required, add the mixture. Fully charged battery be removed from charging machine, allow to cool down and topped up with gel+acid mixture
Carry out at least three charge/discharge cycles as explained
in the green plate battery activation process.
During battery servicing/maintenance topping be done with
Shedding of active material from positive plates is more
serious problem in diesel vehicles and large size traction
batteries because these batteries are used at high discharge
We are pleased to offer this new technology for your batteries. We welcome your questions about ELECTROGEL. We look forward to your interest.
Please write to:
Video of ELECTROGEL: http://www.youtube.com/watch?v=tJFkRyvkRgY
WE ARE THE ONLY MANUFACTURER IN THE WORLD TO HAVE DEVELOPED SYNTHETIC POLYMER GEL ELECTROLYTE FOR LEAD ACID