DRY LEAD ACID BATTERY
[EIRI/EDPR/4522] J.C.: 2739INR,2739US$
Lead Acid Storage Batteries is an electro-chemical system that converts electrical energy into direct current electricity. It is also known as storage batteries and has wide applications in Automobiles, UPS/Inverters, Traction/Electrical Sub-Station, Telecommunication, Solar Photovoltaic system etc.
Working Principle of Lead Acid Battery
The storage battery or secondary battery is such battery where electrical energy can be stored as chemical energy and this chemical energy is then converted to electrical energy as when required. The conversion of electrical energy into chemical energy by applying external electrical source is known as charging of battery. Whereas conversion of chemical energy into electrical energy for supplying the external load is known as discharging of secondary battery. During charging of battery, current is passed through it which causes some chemical changes inside the battery. This chemical changes absorb energy during their formation.
When the battery is connected to the external load, the chemical changes take place in reverse direction, during which the absorbed energy is released as electrical energy and supplied to the load. Now we will try to understand principle working of lead acid battery and for that we will first discuss about lead acid battery which is very commonly used as storage battery or secondary battery.
COST ESTIMATION
Plant Capacity 500 Nos/Day
Land & Building (8000 sq.mt.) Rs. 4.62 Cr
Plant & Machinery Rs. 2.50 Cr
Working Capital for 1 Month Rs. 7.00 Cr
Total Capital Investment Rs. 14.42 Cr
Rate of Return 25%
Break Even Point 58%
CONTENTS
INTRODUCTION
WORKING PRINCIPLE OF LEAD ACID BATTERY
TYPES OF LEAD ACID BATTERY
CONSTRUCTION AND COMPONENTS OF DRY LEAD ACID BATTERY
CONSTRUCTION
LEAD ACID BATTERY DIAGRAM
CONTAINER
PLATES
ACTIVE COMPONENT
SEPARATORS
BATTERY EDGES
DIFFERENCES BETWEEN FLAT PLATE AND TUBULAR LEAD ACID BATTERY
THE FLAT PASTED PLATE
TUBULAR PLATE
BATTERIES MADE FROM TUBULAR PLATES HAVE THE FOLLOWING CHARACTERISTICS:
MERITS OF VENTED BATTERY
DEMERITS OF VENTED BATTERY
APPLICATIONS:-
2. SEALED LEAD-ACID BATTERIES
THERE ARE TWO TYPES OF SEALED LEAD ACID BATTERY
MERITS SEALED LEAD ACID BATTERY
DOES NOT REQUIRE WATER TOP-UP THROUGHOUT ITS LIFE
DEMERITS OF LEAD BATTERY
APPLICATIONS OF VALVE-REGULATED BATTERIES
USES AND APPLICATION
B.I.S. SPECIFICATION
GLOBAL MARKET OF LEAD ACID BATTERY
MANUFACTURERS/SUPPLIERS OF LEAD ACID BATTERY
PAKISTAN BATTERY MARKET
LITHIUM-ION BATTERY EXPECTED TO WITNESS SIGNIFICANT GROWTH
STEPS IN BATTERY MANUFACTURING PROCESS
BATTERY INNER STRUCTURE
MAIN PARTS OF THE BATTERY
MANUFACTURING STEPS OF LEAD-ACID BATTERIES
1. OXIDE AND GRID PRODUCTION PROCESS
GRID CASTING PROCESS
2. PASTING AND CURING
BATTERY PLATES AFTER PASTING AND CURING
3. ASSEMBLING THE ELEMENTS
BATTERY PLATES STACKING
ASSEMBLING THE ELEMENTS OF BATTERY
4. FILLING AND FORMATION
MANUFACTURING PROCESS IN DETAILS
LIST OF RAW MATERIAL
THERE ARE FOLLOWING STEAPS ARE USED FOR MANUFACTURING LEAD ACID BATTERY
(1) MANUFACTURING PLASTIC CONTAINER AND COVER
MANUFACTURING PROCESS OF PVC/ABS BATTERY CONTAINER
PLATE PREPARATION
THE FLAT PASTED PLATE
TUBULAR PLATE
MANUFACTURING PROCESS OF TUBULAR PLATES
MANUFACTURING PROCESS OF FLAT PLATE
(A) LEAD OXIDE PREPARATION
PROCESS:
THE FOLLOWING ARE TESTED TO EVALUATE THE QUALITY OF LEADY OXIDE
(B) GRID CASTING:
TYPES OF GRIDS:
COMMON DEFECTS IN GRIDS
TESTING OF GRIDS:
BEND TEST:
BUS BAR CASTING:
(C) PASTE PREPARATION
FOR POSITIVE PASTE:
FOR NEGATIVE PASTE:
PASTING PROCESS
(D) CURING AND DRYING:
CURING AND DRYING IS DONE AT THREE STAGES.
(3) ASSEMBLY
A. GROUP STACKING:
B. GROUP BURNING:
C. GROUP STRAPPING:
D. GROUP INSERTION:
E. HEAT SEALING:
F. POST BURNING:
G. LEAK TESTING:
(4). FORMATION
A. CELL PACKING:
B. ACID FILLING:
(5) TESTING OF BATTERY
(A) STATIC BATTERY VOLTAGE TEST
(B) STARTING LOAD TEST
(C) CHARGING SYSTEM TEST
(D) AIR LEAKAGE TESTING:
THERE ARE THREE TYPES OF AIR LEAKAGE SYSTEMS AVAILABLE MAINLY:
MANOMETER IS VERY OLD TECHNOLOGY & THIS CANNOT BE USED FOR FAST OPERATION
AIR TESTER
6. FINISHING & DESPATCHING:
PROCESS FLOW CHART
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSURE
SUPPLIERS OF PLATEFARM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF RAW MATERIAL
SUPPLIERS OF ANTIMONIAL LEAD
SUPPLIERS OF LEAD OXIDE
SUPPLIERS OF NATURAL RUBBER
SUPPLIERS OF PVC BATTERY SEPARATORS
SUPPLIERS OF LEAD INGOTS
SUPPLIERS OF PVC GRANULES/PVC MASTER BATCHES
SUPPLIERS OF SULPHURIC ACID
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
