10-03-2023

Gas emission from Wet/Flooded Pb-Acid Battery

If the charging current is too great, electrolysis will occur, decomposing water
into hydrogen and oxygen, in addition to the intended conversion of lead
sulfate and water into lead dioxide, lead, and sulfuric acid (reverse of the
discharge process).

Gas emission from Wet/Flooded Pb-Acid Battery

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VRLA Batteries (Valve Regulated Pb-acid Batteries)-1

The valve regulated lead–acid (VRLA) battery have the same chemistry of wet cell Pb-acid battery, except
the electrolyte is immobilized.

Standard Pb-acid batteries employ Lead-alloys as plates in the form of bars ( Calcium or Magnesium are used to
make the alloy). These are placed being dipped inside the liquid electrolyte and electron exchange takes place by
direct contact between the electrolyte and the plates.
Limited amount of electrolyte ("starved" electrolyte) absorbed in a plate separator or formed into a gel; proportioning
of the negative and positive plates so that oxygen recombination is facilitated within the cell.
Under normal operating conditions the gases can recombine within the battery itself, sometimes with the help of a
catalyst, and no additional electrolyte is needed.
Each cell has a pressure relief valve which will activate when the battery starts building pressure of hydrogen gas,
generally a result of being recharged.
In contrast to the flooded Pb-acid batteries, VRLA batteries retain generated gases within the battery as long as the
pressure remains within safe levels.
If the pressure exceeds safety limits, safety valves open to allow the excess gases to escape, and in doing so
regulate the pressure back to safe levels (hence "valve regulated" battery).
Two types of VRLA batteries: Gel cell (gel battery) and absorbent glass mat (AGM) cell batteries. Also called
VRSLAB (Valve Regulated Sealed Lead-Acid Battery)

VRLA Batteries (Valve Regulated Pb-acid Batteries)-2

Two types of VRLA batteries: Gel cell (gel battery) and absorbent glass mat (AGM) cell batteries. Also called
VRSLAB (Valve Regulated Sealed Lead-Acid Battery)

Gel cell (gel battery):

Contains a mixture of H2SO4 and finely divided silica. Mixture forms a thick paste or gel, which
makes the resulting mass gel like immobile ( so named - Gel Cell).
Chemically the same as wet (non sealed) batteries except that the antimony in the lead plates is
replaced by calcium, and gas recombination can take place.
Positive plates may be flat or tubular. Unlike a flooded wet cell lead–acid battery, these batteries do
not need to be kept upright.
Gel batteries reduce the electrolyte evaporation, spillage (and subsequent corrosion problems)
common to the wet cell battery, and boast greater resistance to shock and vibration.

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VRLA Batteries (Valve Regulated Pb-acid Batteries)-3

Absorbent Glass Mat (AGM) battery:
Each cell of the battery has two pure thin lead plates- positive electrode and negative electrode.
In between the lead plates, there is an AGM separator. It holds and absorbs the liquid electrolyte.
calcium added to its plates to reduce water loss

AGM separator :
thin ultra-fine fiberglass mat sandwiched between the plates that are saturated with battery acid
to about 95% of what they can hold the electrolyte (non-spillable) and separates the plates.

Very thin glass fibers are woven into a mat to increase the surface area enough to hold a
sufficient amount of electrolyte on the cells for their lifetime. The fibers that compose the fine
glass mat do not absorb and are not affected by the acidic electrolyte.
The plates and mats are packed fairly tight, they are almost immune to vibration. All these are
highly compressed and closely packed to each other. It acts as a single cell with two terminals. The
outermost side of the plates has grids.

The plates in an AGM battery may be of any shape. Some are flat, whereas others are bent or
rolled. Both deep cycle and starting type of AGM batteries, are built into a rectangular case.
There are six cells that are interconnected to each other in a series connection.

VRLA Batteries (Valve Regulated Pb-acid Batteries)-4

Using a recombination reaction to prevent the escape

of H2 and O2 gases.

The O2 produced from the positive plates of the

battery is absorbed by the negative plates.

The recombination of O2 and H2 leads to water (H2O,

retaining the electrolyte amount within the battery. So
water filling is never required.

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Advantages and Disadvantages of VRLA batteries--5

Advantages and Disadvantages:

The gel provides a better means of heat conduction from the plates to the cell walls than in
AGM batteries. Since the heat produced on overcharge is lost more efficiently, they are
suitable for deep cycle applications.
AGM batteries, on the other hand, offer fastest charging rate, offer long service life.
The term "maintenance free" is a misnomer as VRLA batteries still require cleaning and
regular functional testing. They are not permanently sealed, but are designated to be
maintenance free.
AGM automobile batteries are typically about twice the price of flooded-cell batteries; gel
batteries as much as five times the price.
Because of calcium added to its plates to reduce water loss, a sealed AGM or gel battery
recharges more quickly than a flooded lead–acid battery of either VRLA or conventional
design.
AGM battery should never be opened as this would damage the battery with additional O 2
from the air.

VRLA batteries vs. Wet cell/ flooded Pb-acid batteries--6

VRLA batteries vs. normal Pb-acid batteries:
1) Have shorter recharge time than flooded lead–acid batteries because of calcium added to its plates to reduce water
loss.
2) Cannot tolerate overcharging: overcharging leads to premature failure.
3) Discharge significantly less hydrogen gas.
4) AGM batteries are by nature, safer for the environment, and safer to use.

5) VRLA batteries can be used or positioned in any orientation and do not require constant maintenance.

6) In contrast to the flooded Pb-acid batteries, VRLA batteries retain generated gases within the battery as long as the
pressure remains within safe levels.

7) VRLA batteries are more vulnerable to thermal runaway during abusive charging. The electrolyte cannot be tested by
hydrometer to diagnose improper charging that can reduce battery life.

8) The VRLA battery can be mounted in any position.

9) To ensure maximum life, a flooded lead–acid battery should be fully recharged as soon after a discharge cycle as
possibcklle to prevent sulfation.

10) Because of calcium added to its plates to reduce water loss, a sealed AGM or gel battery recharges more quiy than a
flooded lead–acid battery of either VRLA or conventional design.

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VRLA batteries vs. Wet cell/ flooded Pb-acid batteries--11

VRLA batteries vs. normal Pb-acid batteries:

11) Compared to flooded batteries, The electrolyte cannot be tested by hydrometer to

diagnose improper charging that can reduce battery life.
12) For VRLA batteries, Lead–calcium alloys harden extremely rapidly;
80% of the ultimate strength is reached in one day and virtually full ageing in seven
days. Such rapid hardening enhances grid handling and battery production.
13) Alloying with Sn or Al in lead-calcium grids produces even better lead acid batteries
since Sn and Al improve castability, mechanical properties, and electrochemical
interactions during battery charging and discharging, and inhibit corrosion;
Effects of high tin on positive-grid corrosion in VRLA batteries improves the cycle-
life and capacity.

A Comparison ---12

Comparison:
Flooded cell lower costs per kWh.
In a gel battery, the volume of free electrolyte that could be released on damage to the case or venting is very small.
No need (or ability) to check the level of electrolyte or to top up water lost due to electrolysis, thus reducing inspection
and maintenance requirements.
Wet-cell batteries can be maintained by a self-watering system or by topping up every three months. The requirement
to add distilled water is normally caused by overcharging.
All lead–acid batteries require a relatively long recharge cycle time arising from an inherent three-stage charging
process: bulk charge, absorption charge, and (maintenance) float charge stages. All lead–acid batteries are quick to
bulk charge to about 70% of capacity during which the battery will accept a large current input, determined at a voltage
setpoint, within a few hours (with a charge source capable of supplying the design C-rate bulk stage current for a given
Ah battery).
To ensure maximum life, a lead–acid battery should be fully recharged as soon after a discharge cycle as possible to
prevent sulfation, and kept at a full charge level by a float source when stored or idle (or stored dry new from the
factory, an uncommon practice today).
This VRLA battery range has a design life of 20 years at 27°C under ideal float condition. The capacity of these
batteries ranges from 200Ah to 6000 Ah at 27°C. The operating temperature range is -5°C to 40°C. These give about
1800 cycles at 50% DOD.

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Separator -----13

The building blocks of a battery are the cathode and anode, and these two electrodes are isolated by a separator.
Separators are microporous diaphragms placed between the negative and positive plates of lead-acid batteries to
prevent any contact between them to avoid internal short circuit but at the same time allow free circulation of the
electrolyte.

The separator is moistened with electrolyte and forms a catalyst that promotes the movement of ions freely from
cathode to anode on charge and in reverse on discharge.

Although ions pass freely between the electrodes, the separator is an isolator with no electrical conductivity. The small
amount of current that may pass through the separator is self-discharge and this is present in all batteries to varying
degrees.
In the maintenance-free lead acid, the electrolyte is absorbed into a porous separator that is compressed against the
electrodes to achieve chemical reaction.

Early separators were made of rubber, glass fiber mat, cellulose and polyethylene plastic. Nickel-based batteries use
separators of porous polyolefin films, nylon or cellophane.
Commercially available Li-ion cells use polyolefin as a separator

The absorbed glass mat (AGM) in the sealed lead acid version uses a fiberglass mat or an ultra thin glass mat as a
separator that is soaked in sulfuric acid.

The earlier gel lead acid converts the liquid electrolyte into a semi-stiff paste by mixing the sulfuric acid with a silica-
gelling agent. Synthetic wood-pulp (SWP) separators used widely

Applications of VRLA Batteries-----14

Modern motorcycles and all-terrain vehicles (ATVs) use AGM batteries to reduce likelihood
of acid spilling during cornering, vibration, or after accidents, and for packaging reasons.
Due to the higher manufacturing costs, currently used on specific vehicles.
VRLA batteries are used extensively in power wheelchairs, as the extremely low gas and
acid output makes them much safer for indoor use.
As vehicles become heavier and equipped with more electronic devices such as navigation
and stability control, AGM batteries are being employed to lower vehicle weight and provide
better electrical reliability compared with flooded lead–acid batteries.
5 series BMWs from March 2007 incorporate AGM batteries in conjunction with devices for
recovering brake energy using regenerative braking and computer control to ensure the
alternator charges the battery when the car is decelerating. Vehicles used in auto
racing may use AGM batteries due to their vibration resistance.

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Applications of VRLA Batteries-----15

Deep-cycle AGMs are also commonly used in off-grid solar power and wind
power installations as an energy storage bank and in large-scale amateur robotics. AGM
batteries are routinely chosen for remote sensors such as ice monitoring stations in
the Arctic. AGM batteries, due to their lack of free electrolyte, will not crack and leak in these
cold environments.
VRLA batteries are used in the uninterruptible power supply (UPS) as a backup when the
electrical power goes off.
VRLA batteries are the standard power source in sailplanes, due to their ability to withstand
a variety of flight attitudes and a relatively large ambient temperature range with no adverse
effects. However, charging regimes must be adapted with varying temperature.
VRLA batteries are used in the US Nuclear Submarine fleet, due to their power density,
elimination of gassing, reduced maintenance, and enhanced safety.
AGM and gel-cell batteries are also used for recreational marine purposes, with AGM being
more commonly available.