P.V.C. BATTERY SEPARATOR
[EIRI/EDPR/1552] J.C. 347
INTRODUCTION
Amongst the various systems and devices that are available for converting electrical energy to some form of storage energy for reconversion to electrical energy, lead storage battery is the most effective system available. The use of storage batteries is far and wide and mainly in the field of automobile, telephone exchange, submarines, aircrafts etc. Before 1946, most separators used in storage batteries were of wood and since then, these have been replaced either by PVC or micrporous rubber which are highly suitable.
Sintered microporous PVC battery separators are the separators used in the storage batteries all over the world for enhancing the life and quality of the battery. The function of a separator is to isolate the positive and negative plates in a battery by providing a perfect insulation, these preventing short circuit in them. At the same time the separators function as a permeable membrane so as to effect circulation of the electrolytes for the chemical reactions and free ionic flow.
The selection of proper separator is important in obtaining maximum utilization of active materials. Formerly wood veneer made out of fir trees were used for this purpose. These veneer was grooved to form ribs and treated in caustic soda. Recently wood has been replaced by treated paper, plastics and rubber. Paper separators are made by treating paper of controlled porosity with phenol formaldehyde resin, curing, corrugating to form the ribs and cutting to sizes rubber separators are made from rubber latex and silica gel. Plastic separators are made from PVC granules sintered together.
When positive and negative groups are interleaved, adjacent plates of opposite polarity must be prevented from touching each other, otherwise a short circuit would develop within the cell. Separators of various materials are inserted between the plates and the assembly of plate groups and separators is called and element.
Battery separators are essential constituents of storage batteries which are placed between positives and negative plates there by preventing their direct contact and at the same time allowing the electrolyte to diffuse through these separators to facilitate electro chemical reaction.
Battery separators made from microporous rubber and properly treated wood were very popular and were being used in the lead, acid storage batteries. They are however suffer from the draw back due to their poor resistance to chemicals. They detericrate when kept in sulphuric acid continuously as in the case with lead storage batteries and thus service life of such batteries are short. PVC has excellent chemical resistance and electrical insulating properties and are ideal for the manufacture of battery separators, having excellent chemical resistance.
PVC separators are expected not to deteriorate under continuous contact with sulphuric acid and therefore storage batteries made from microporous PVC separatore give long continuous service. Consequently, modern tendency is to use microporous to wooden or rubber.
COST ESTIMATION
Plant Capacity 50,000 Nos/Day
Land & Building (1500 sq.mt.) Rs. 1.29 Cr
Plant & Machinery Rs. 60.00 Lac
Working Capital for 2 Months Rs. 51.37 Lac
Total Capital Investment Rs. 2.71 Cr
Rate of Return 31%
Break Even Point 57%
CONTENTS
INTRODUCTION
PROPERTIES OF PVC SEPARATORS
USES AND APPLICATIONS
PROPERTIES OF SEPARATORS
B.I.S. SPECIFICATION
MARKET POTENTIAL
DETAILED EXPORT DATA OF BATTERY SEPARATORS
PVC BATTERY SEPARATORS FROM INDIA
MANUFACTURING PROCESS
QUALITY CONTROL
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
SUPPLIERS OF RAW MATERIASLS
SUPPLIERS OF PLANT AND 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)
