LEAD ACID BATTERY
[EIRI/EDPR/1394] (J.C.:171)
INTRODUCTION
Lead-Acid Battery comprises number of cells in a container. These cells contain positive (PbO2) and negative (Pb) electrodes or plates separators to keep the plate apart and sulphuric acid electrolyte. The electrochemical system is highly reversible and sulphuric acid electrolyte. The electrochemical system is highly reversible and can be discharged and charge repeatedly before failure of some sort causes the chargocyde to be impractical.
There are numerous battery designs. The most widely used secondary battery is the lead acid type. This battery is available in many sizes and capacities and the weight can vary from 100g to several tons, There on three principal categories.
Automotive: SLI (Starting, Lighting and ignition) for cranking of eternal combustion engines. This is the major application of the lead-acid battery.
Industrial: Heavy-duty applications such as motive power and standby power.
Consumer: Emergency lighting and security alarm systems, cordless convenience devices and power tools and small engine starting.
CONTAINER:-
The material used for containers used depends on the application e.g. polypropylene and vulcanized rubber for automotive batteries, polystyrene for stationery batteries, polycarbonate for a large single cell and ABS plastic and drawn steel cans for sealed lead cells. All plastic and rubber containers are molded.
The container serves to hold the battery contents without determination, to allow the cell plates to rest on the bottom ridges and to separate the cells, in some cases by compartment positions.
Physical qualities are required of the container are; to resist attack by sulphuric acid solution and the battery components, to be nonporous, be nonreactive and to withstand extremes of heat and as well as shock and vibration.
Separator:-
To prevent contact of the positive and negative plate a separator is placed between then. These separators are usually in sheet form and are commonly made of paper, rubber, glass or plastic. Since sulphuric acid must permeate the separator, it must be microporous. The separators are generally ribbed on the side placed towards the positive plate. This procedure prevents excessive separator contact with the oxidizing positive plate material and it allows a greater volume of sulphuric acid to be used by the positive plate during discharge.
Sulphuric Acid:-
The dilution of sulphuric acid must be done with adequate cooling because of dilution process is highly exothermic. Each manufacturer selects a particular sulphuric acid concentration which is compromise between the grid corrosion and battery performance.
Plates are the components/parts of a storage battery cell and lead storage plates are divided broadly into types designated by the names of their respective makers the formed and pasted types.
In the formed type the active material consists of a comparatively thin layer superficially formed by an electro chemical process from the metallic lead of the supporting grid. To obtain the desired capacity a highly developed grid surface is essential.
COST ESTIMATION
Plant Capacity 1680 Nos/Day
Land & Building (5000 sq.mt.) Rs. 5.30 Cr
Plant & Machinery Rs. 1.30 Cr
Working Capital for 1 Month Rs. 26.90 Cr
Total Capital Investment Rs. 33.82 Cr
Rate of Return 73%
Break Even Point 33%
CONTENTS
INTRODUCTION
MARKET POSITION
LEAD ACID BATTERY MARKET IN INDIA 2013
PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS
B.I.S. SPECIFICATION
BATTERY PLATE RAW MATERIALS AND THEIR PROPERTIES
PROPERTIES OF GRID ALLOYS USED IN SLI AND SEALED LEAD BATTERIES
CASTABILITY OF GRID ALLOYS
MANUFACTURING OF PVC BATTERY CONTAINERS
LEAD-ACID STORAGE BATTERY ASSEMBLING
PVC BATTERY SEPARATOR
B.I.S. SPECIFICATION FOR SEPARATOR
MANUFACTURING PROCESS
MANUFACTURING PROCESS OF LEAD ACID BATTERY CONTAINERS
DETAILS OF MANUFACTURING PROCESS OF PVC BATTERY CONTAINER
ASSEMBLY OF BATTERY
TESTING OF BATTERY
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
ADDRESSES OF RAW MATERIAL SUPPLIERS
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
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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