Electrogel And Batcure
Patrick Bailey ine@ padrak.com
NEN SEP 2004 Part 2
Electrogel And Batcure
You may find these innovations from India for recycling batteries helpful.
The Planetary Association for Clean Energy, Inc.
100 Bronson Avenue, Suite 1001
Ottawa, Ontario K1R 6G8 Canada
From: "Suresh" KV045@ hotmail.com
Wed, 4 Aug 2004
Subject: ELECTROGEL AND BATCURE
ELECTROGEL (SYNTHETIC POLYMER GEL ELECTROLYTE)
WHAT IS ELECTROGEL?
ELECTROGEL is a viscous water white synthetic polymer gel electrolyte FREE
from SILICA. It is soluble in water, acid and other ionic solvents. It is
manufactured using specilaty chemicals and proprietory process for the first
ELECTROGEL is a revolutionary product for the battery industry. It is non
corrosive, stable, odour free, non-hazardous, non-flammable.
WHY ELECTROGEL FOR BATTERIES?
The two major problems related to lead acid batteries are CORROSION and
SULPHATION. Unless and until non-corrosive electrolyte is developed for the
batteries, these two problems continue to limit the life and performance of
the batteries. It is therefore very important to minimise the negative role
of sulphuric acid as an electrolyte for the batteries.
ELECTROGEL is developed to meet the challenges posed by highly corrosive
sulphuric acid for the battery.
ELECTROGEL offers following major advantages to battery.
(1) PROTECTS POSITIVE PLATES FROM CORROSION.
(2) PROTECTS NEGATIVE PLATES FROM SULPHATION.
(3) PROTECTS PLATES FROM EXTERNAL AND INTERNAL HEAT.
(4) PROTECTS ACTIVE MATERIALS FROM SHEDDING.
(5) VERY LOW WATER loss.
(6) PROTECTION AGAINST DEEP DISCHARGES.
(7) LONG LIFE BATTERY.
(8) ENVIRONMENT FREINDLY BATTERY.
(9) ALL WEATHER BATTERY.
HOW ELECTROGEL PREVENTS CORROSION AND SULPHATION? ELECTROGEL when filled
into the new battery along with sulphuric acid, it utilises the power from
the charged plates and turns into a viscous gel within 3 to 4 hours
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 ionic 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 is elimininated 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:
Formed positive plates tend to shed active materials during battery
manufacturing process. It also increases the fine dust in the plant and is
hazardus to the working conditions. The dark black material also sticks to
the hands and body of the workers.
To eliminate this problem applied with 10% ELECTROGEL solution in water. On
drying, the fine adhesive film will form on +ve plate active materials which
will prevent the shedding of active materials.
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 flate plates, ELECTROGEL helps to enhance the life of the battery.
HOW TO USE ELECTROGEL IN BATTERY?
Prepare a mixture of ELECTROGEL and sulphuric acid (15% ELECTROGEL+ 85
%SULPHURIC ACID of 1300 S.G for automotive battery and 1350 S.G. for
industrial battery).Final S.G. of mixture will be 1260 for automotive
battery and 1290 for industrial battery. ELECTROGEL and acid must be
Filling of ELECTROGEL + ACID mixture into a new battery should be done
carefully to avoid excessive heat and gas generation. We strongly recommend
that batteries to be filled with mixture must therefore be immersed into
cold water bath up to plate height. Water bath temp. should 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 up to plate height.(If water bath is not used then gel
mixture with flow out of battery due to heat and gas). Cooled batteries be
then put to charging using either constant current or constant voltage
charger. Normal charging procedure be followed. During charging process if
topping up is required, add the mixture. Fully charged battery be removed
from machine, allow to cool down and topped up with mixture. During battery
serviceing/maintenance topping be done with distilled water.
We are pleased to offer this new technology for your batteries.
We welcome your any questions about ELECTROGEL.
We look forward to your INTEREST.
WE ARE THE ONLY MANUFACTURER IN THE WORLD TO HAVE DEVELOPED SYNTHETIC
POLYMER GEL ELECTROLYTE FOR LEAD ACID BATTERIES PROTECTION AND PREVENTION
AGAINST BATTERY FAILURE
(SULPHATION INHIBITOR CUM SULPHATION REMOVER)
REVIVE YOUR SICK,WEAK,SULPHATED BATTERIES WITH BATCURE AND SAVE MONEY.
Application of BATCURE in -ve plate paste formulation.
1 ml BATCURE per kilo gram of Lead Oxide is recommended for addition to
a -ve paste prepration. Add required quantity of BATCURE in water. Then add
to Lead Oxide with other additives. You can stop adding Barium Sulphate and
Lignine to negative paste. Mix it well for 20 to 30 minutes before starting
the addition of acid. Carry out controlled addition of acid to ensure that
heat generation is minimum. Use cold water jacketed mixture for cooling.
Addition of BATCURE to -ve plate paste helps to prevent sulphation of -ve
plates, uniform charge distribution, faster charging, improved electrocast
of -ve plates and complete conversion of paste into active sponge lead.
Application of BATCURE in preventing aerial oxidation of -ve plates:
As the formation process continues the negative paste active materials turn
from non-conductive to conductive spongy lead and are being electrocast to
pure spongy lead. The spongy lead formed from active materials is free from
OXYGEN and SULPHATE ions.
The spongy lead is highly deficient of OXYGEN and in an unstable form having
developed -ve Volts up to - 0.3 Volts. Therefore when freshly formed -ve
plates when removed from formation jars and washed with water (pH 5 to 6 of
washed -ve plates) the negative plates begin to absobe OXYGEN from the air.
This is called the AERIAL OXIDATION OF FRESHLY FORMED -VE PLATES. The oxygen
from air combines with spongy lead with EXOTHERMIC REACTION and reforms the
Lead Oxide with loss of negative plate volts.
It is therefore very important to protect -ve plates from aerial oxidation
after the formation is completed. If the necessary precatutions are not
taken to protect the ve plates from oxidation, the plates will continue to
absobe more and more oxygen from air even after they come to room
temperature and will loss the -ve plates volts. In this condition the -ve
plates will be more susceptible to SULPHATION also. The shelf life of -ve
plates and the battery made out of such plates will be very poor and may
require prolonged recharging to activate the batteries.
In order to prevent aerial oxidation of -ve plates after formation is
completed, the -ve plates are dried only in inert medium having no oxygen(
Nitrogen Gas Chamber).If you do drying of -ve plates in simple heating
chamber then you are doing more damage to the -ve plates as it adds to
exothermic reaction which already begins on its own.
In order to save -ve plates from aerial oxidation a more simple and
economical method is to dip freshly formed -ve plates into a solution
containing 15 to 20 ml. BATCURE per litre of water for 4-5 hours or more.
The -ve plates should not be washed before or after dipping into the
solution. The anti-oxidation film formed on the -ve plates protects the -ve
plates from aerial oxidation as no heat generation takes place when immersed
plates taken out and allowed to dry at room temperature in less ventilated
room. The film so formed on -ve plates also helps to check SULPHATION and
increased shelf life of -ve plates at room
temperature. The above procedure is very simple, cost saving, and eliminates
the need for a time consuming costly DRY CHARGE PROCESS. Negative plates
charge retention has been found to be more 70% with BATCURE treatment.
The strength of solution be maintained periodically by addion of BATCURE and
water. We recommend to add 50 ml. BATCURE for a 100 litre solution per 1000
standard size -ve plates.
Addition of BATCURE for assembled batteries:
Battery assemblers should use 2.5 ml. BATCURE per litre of acid ( S.G.1220
to1240) to remove partial sulphation from -ve plates and faster battery
The acid containing BATCURE will also help to prevent SULPHATION at later
stage of battery service life. Addition of BATCURE to remove SULPHATION:
The premature capacity loss of a battery is mostly attributed to SULPHATION
of -ve plates. The sulphated battery does not hold charge, when put to
charging it begins gassing heavily, no increase in electrolyte gravity and
heat generation are some of the symptoms of SULPHATED battery. To revive
sulphated battery we recommend following procedure.
For wet batteries:
First find out the volume of electrolyte in each cell from battery
manufacturer's battery specification. Add 5ml. BATCURE per litre of acid
volume in each cell. Mix it well with hydrometer. Reddish yellow colore will
develope. Keep the battery under idle condition for 12 hours. The acid will
again become colorless. If the cell has been mechanically damaged no
discoloration will take place (Such battery must be discarded).If cells are
heavily sulphated it will take more time for discoloration. When all cells
have no color in the acid, the battery should be charged fully. Depending on
sulphation percentage, at least 3 to 5 charge/discharge
cycles be conducted to remove complete sulphation.(No BATCURE addition
required for every time you do cycling).
BATCURE treatment be carried out as soon as the sulphation is observed or
the battery back up graph shows downward storage capacity. Does not require
to change the acid from the batteries. On line addition of BATCURE
(preferably when batteries are in discharged state) will help to revive very
large batteries up to 16000 Ampere-hour capacity.
For VRLA type mainenance free sealed batteries.
Most of the VRLA type sealed mainetance free batteries fail to deliever
power or report a premature capacity loss due to failure of recombination
mechanisam(due to sulphation of -ve plates),drying out of immobilised
electrolyte, stratification, etc.
Such batteries should be give BATCURE treatment immediately once the storage
capacity graphs shows downward trend.
Carefully break open the seals and remove the rubber cap from vent holes.
Inject first BATCURE using doctor's plastic syringe. For 5 AMP to 10 AMP
battery use 0.5 ml BATCURE in each cell, use 1 ml per cell for 11 AMP to 20
AMP, and for every 10 AMP increase 1 ml BATCURE addition. Then add
sufficient quantity of distilled water up to plate height. Close the rubber
cap and tilt the battery for few times to mix the solution inside the
battery. Remove the cap. Allow the battery to rest for 12 hours. Then carry
out 3 to 5 charge /discharge cycles to remove the sulphation and bring it
back to full capacity. Recap the battery with rubber caps. Reseal the
battery with adhesives.
Do not try BATCURE on preganant (bulged) battery. They are explosive and
could release gasses that may damage the person.
SURESH PANDYA K.V.INTERNATIONAL,
405, ABHISHEK CENTRE, SECTOR-11,
FAX ; 0091793232070 MOBILE ;OO91-9824035699
email : kvintll@ hotmail.com
For live discussion click ICQ 349601255.
We will reply to all your battery questions.
WE ALSO MANUFACTURE "BATCURE" SULPHATION INHIBITOR CUM SULPHATION REMOVER TO
REVIVE THE SICK ,WEAK, UNSERVICEABLE BATTERIES.