Detailed Project Report on P.V.C. Battery Separator

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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 Recently wood has been replaced by treated paper, plastics and rubber.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)

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