Detailed Project Report on Lead Acid Battery- Maintenance Free Battery (Valve Regulated Lead Acid Battery)

LEAD ACID BATTERY- MAINTENANCE FREE BATTERY (VALVE REGULATED LEAD ACID BATTERY)

[EIRI/EDPR/1673] J.C. 492

INTRODUCTION

A VRLA battery (valve-regulated lead-acid battery), more commonly known as a sealed battery or maintenance free battery, is a type of lead-acid rechargeable battery. Due to their construction, they can be mounted in any orientation, and do not require constant maintenance.[1] The term "maintenance free" is a misnomer as VRLA batteries still require cleaning and regular functional testing. They are widely used in large portable electrical devices, off-grid power systems and similar roles, where large amounts of storage are needed at a lower cost than other low-maintenance technologies like lithium-ion.

There are two primary types of VRLA batteries, gel cells and AGM. Gel cells add silica dust to the electrolyte, forming a thick putty-like gel. These are sometimes referred to as "silicone batteries". AGM, short for "absorbed glass mat", batteries feature fiberglass mesh between the battery plates which serves to contain the electrolyte. Both designs offer advantages and disadvantages compared to conventional batteries, as well as each other.

AGM (Absorbed glass mat)

AGM batteries differ from flooded lead acid batteries in that the electrolyte is held in the glass mats, as opposed to freely flooding the plates. Very thin glass fibers are woven into a mat to increase surface area enough to hold sufficient electrolyte on the cells for their lifetime. The fibers that compose the fine glass mat do not absorb nor are they affected by the acidic electrolyte. These mats are wrung out 2–5% after being soaked in acids, prior to manufacture completion and sealing.

The plates in an AGM battery may be any shape. Some are flat, others are bent or rolled. AGM batteries, both deep cycle and starting, are built in a rectangular case to BCIbattery code specifications.

Disassembled AGM battery. From left: positive plate, glass mat separator, negative plate. On the right are the five remaining cells (of the six-cell battery).

COST ESTIMATION

Plant Capacity            1680 Nos/Day

Land & Building (5000 sq.mt.)    Rs. 5.30 Cr

Plant & Machinery                    Rs. 1.76 Cr

Working Capital for 1 Month    Rs. 26.96 Cr

Total Capital Investment          Rs. 34.34 Cr

Rate of Return                          40%

Break Even Point                      47%

CONTENTS

INTRODUCTION

B.I.S. SPECIFICATION

MARKET SURVEY

LEAD ACID BATTERY MARKET IN INDIA 2013

SMF VRLA BATTERIES IN DEMAND

PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS

CONSTRUCTION OF LEAD ACID BATTERY

MANUFACTURING PROCESS

THE LEAD OXIDE MANUFACTURING PROCESS

MANUFACTURING PROCESS OF BATTERY CONTAINERS

RECIPROCATING SCREW INJECTION CYLINDER

DETAILS OF MANUFACTURING PROCESS OF BATTERY CONTAINER

ASSEMBLY OF BATTERY

TESTING OF BATTERY

SPECIFICATION FOR VALVE REGULATED LEAD ACID BATTERIES FOR 110V TRAIN-LIGHTING, AIR CONDITIONED AND LHB COACHES

MAXIMUM DIMENSIONS AND WEIGHTS OF MODULES/TRAY

SCHEDULE OF DESIGN PARTICULARS

SCHEDULE OF PERFORMANCE

SAMPLE FOR TYPE TESTING

SAMPLING PROCEDURE FOR ACCEPTANCE TESTS

PROCESS FLOW SHEET DIAGRAM

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT & MACHINERY

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)