Dry Lead Acid Battery (500 Numbers Per Day)

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)