12V27A battery

At present, what do the key technologies and equipment for recycling and regenerating waste 12V27A battery mainly rely on?

1. Promotion of technology

1. Mercury-free button alkaline zinc-manganese battery technology and equipment Mercury-free button alkaline zinc-manganese battery key technologies mainly include battery steel shell structure and surface coating treatment, negative amalgam-free alloy zinc powder material, positive manganese dioxide material and electrolyte process formula, with mercury content less than 0.0005%. The key indicators are leak-proof and storage performance. The promotion of this technology can achieve mercury-free button alkaline zinc-manganese batteries, reducing mercury consumption by 110 tons per year. At present, the annual output of button alkaline manganese batteries has reached more than 8 billion, of which 10% have achieved mercury-free.

2. Mercury-free, cadmium-free and lead-free technology for cardboard zinc-manganese batteries Mercury-free, cadmium-free and lead-free cardboard zinc-manganese batteries, that is, mercury, cadmium and lead content are less than 0.0005%, 0.002% and 0.004% respectively. The key points of this technology are that the negative electrode zinc cylinder alloy components and mechanical processing performance, organic and inorganic additives are combined into corrosion inhibitors to replace mercuric chloride, electrolyte and positive electrode formula. At present, the output of paperboard zinc-manganese batteries is about 18 billion, of which nearly 10% of the products have achieved mercury-free, cadmium-free and lead-free. The promotion of this technology can use the existing production lines to achieve mercury-free, cadmium-free and lead-free paperboard zinc-manganese batteries, reducing the annual consumption of lead by 336 tons, cadmium by 118 tons, and mercury by 4 tons.

3. Winding sealed lead-acid battery technology This technology adopts extended lead grid and winding electrode structure to improve the high current discharge performance and high and low temperature performance, improve the power density of 12V27A battery, and reduce the lead consumption per unit power density by 1/4. Winding sealed 12V27A battery can replace existing starting 12V27A battery and are used in the fields of ordinary automobiles and engineering vehicles. They can also be used as power batteries in mild hybrid electric vehicles and lightweight electric vehicles. At present, this technology has formed mass production capacity.

4. Grid-drawing, punching, continuous casting and rolling lead-acid battery plate manufacturing process technology and equipment The positive and negative plates of 12V27A battery are made of grids as carriers of active substances. Grid-drawing grid technology uses cold extrusion to make the grid metal structure dense, significantly improve corrosion resistance, and the grid is thinner than other processes, reducing lead consumption and reducing lead smoke and lead slag emissions. New grid manufacturing technologies also include punching and continuous casting and rolling process technologies. Currently, the above processes are mainly achieved through the introduction of foreign technology and equipment to achieve large-scale production.

5. Cadmium-free lead-acid battery technology Cadmium-free technology uses lead-calcium multi-element alloys or other cadmium-free grid alloys to replace cadmium-containing grid alloys, with a cadmium content of less than 0.002%. The promotion of this technology can reduce cadmium consumption by 1,800 tons per year and eliminate the risk of cadmium pollution in the production, recycling and regeneration of 12V27A battery. Currently, cadmium-free 12V27A battery account for about 15% of electric bicycle batteries.

6. Lead-acid battery internal formation process technology At present, some automobile starting batteries, electric bicycle batteries and other products use external formation process, which produces a large amount of acid mist and acid-containing lead wastewater. The promotion of lead-acid battery internal formation process can greatly reduce the generation of lead-containing acid wastewater and acid mist, and reduce the annual discharge of lead-containing wastewater by about 6 million tons.

II. Application technology

1. Paste zinc-manganese battery mercury-free technology Paste zinc-manganese battery is a low-priced traditional product with a total output of about 4 billion. Its characteristics are that the positive electrode uses natural manganese dioxide or active manganese dioxide, but the material has many impurities and it is very difficult to achieve mercury-free. Mercury-free technology mainly includes improving the purity of positive electrode materials, using new materials, adjusting the electrolyte formula, replacing mercuric chloride with a combination of inorganic and organic additives, and using existing production lines to achieve mercury-free products. The promotion of this technology can reduce the annual consumption of mercury by 22 tons. The technology has been successfully developed and can be applied for demonstration.

2. Externalization of lead-acid battery plates without washing process The washing process after the externalization of lead-acid battery plates produces a large amount of lead-containing and acid-containing wastewater. The externalization of lead-acid battery plates without washing process uses a special treatment liquid, or uses the method of discharge and reverse charging protection to treat the formed plates, so as to achieve the purpose of externalization of the plates without washing, and can reduce the discharge of lead-containing wastewater by 90%. At present, this technology has been successfully developed and has the conditions for pilot application.

III. R&D technology

1. R&D of mercury-free technology for silver oxide batteries Silver oxide batteries are mainly used in high-end electronic watches and electronic instruments. The mercury content is about 1% of the battery weight, but they enter the environment directly after being discarded, which poses a pollution risk. In the absence of a recycling and treatment mechanism for silver oxide batteries, it is necessary to start from the source and accelerate the development of new zinc powder alloys, mercury substitute additives, electrolyte process formulas, and battery steel shell structures and surface treatment process technologies to achieve mercury-free silver oxide batteries.

2. R&D of new lead-acid battery technology The development direction of new 12V27A battery is to reduce lead consumption, improve battery mass energy density, mass power density, cycle life and fast charging capability. At present, the focus is on the research of high-performance electrode materials and preparation methods, new battery structures and manufacturing processes, and improving energy density and power density. New 12V27A battery include bipolar sealed batteries, super batteries, foamed graphite batteries, etc., including: (1) Bipolar sealed batteries. This battery adopts a bipolar structure and uses a new ceramic material as a diaphragm. Compared with traditional batteries, it consumes less lead, is light in weight and small in size. It has the characteristics of long cycle life, high charge and discharge efficiency, low price, and easy recycling. (2) Super battery. Carbon is used to partially or completely replace the lead in the negative electrode. This type of battery has the characteristics of long cycle life, high charge rate, good power characteristics, excellent low temperature performance, and light weight. It can be used as a power source for electric vehicles. (3) Foamed graphite battery. The technical innovation of the foamed graphite grid sealed battery is that it abandons the lead grid, retains the active material, and uses foamed graphite instead of lead, which reduces the lead by 70% compared with ordinary 12V27A battery.

3. Research on lead reduction technology for power 12V27A battery and select lead reduction additives and desulfation additives to reduce the polarization of 12V27A battery during discharge, overcome the sulfation of the plate surface, reduce the internal resistance of the battery, improve the power characteristics of 12V27A battery, reduce the capacity of 12V27A battery used in high power such as start-up type, and reduce the lead consumption by more than 10% on the existing basis. Lead reduction technology includes the use of ultra-thin plate technology. This technology has been maturely applied abroad, and is still in the research and development stage in my country.

4. Large-scale harmless recycling and regeneration technology for waste 12V27A battery The risk of lead pollution in the recycling and regeneration of waste 12V27A battery is relatively high. At present, the key technical equipment for the recycling and regeneration of waste 12V27A battery mainly relies on imports. It is necessary to increase the research and development of core technical processes and equipment with independent intellectual property rights in mechanical crushing, sorting, lead paste desulfurization, lead regeneration and other links, develop comprehensive prevention and control and utilization technology and equipment for wastewater, waste gas and waste residue pollution, and realize large-scale harmless recycling and utilization of waste 12V27A battery.

When UPS manufacturers configure batteries, the design capacity they choose fully meets or even exceeds the power capacity and power supply time requirements for the load to be powered without interruption. However, after the UPS is put into operation, users often find that the actual time the UPS can provide power without interruption after a power outage is much less than the design value. The reason for this phenomenon is that in most cases, it is not because the backup capacity of the battery is insufficient when it is initially configured, but because the capacity of the battery is not fully utilized. There are many reasons for the reduction in the actual capacity of the battery, including battery quality problems, but more importantly, usage and maintenance problems.

(1) Battery capacity

During the manufacturing process of lead-acid battery plates, the raw plates are charged and converted to lead dioxide on the positive plate and sponge lead on the negative plate. However, the manufacturer has limited time to convert the plates, and it is impossible to convert all substances into active substances. For this reason, the national standard stipulates that a new battery is qualified when it reaches 90% capacity. Only in subsequent daily use does the capacity gradually reach the normal value, and it is required to reach 100% two years after installation.

The rated capacity of the battery pack is obtained under the specified discharge rate. The discharge rate (1/H) = discharge current (A) / battery rated capacity (Ah). For example, one of the typical specifications of the small battery used in the UPS power supply is 12V, 6Ah/2Ohv. This specification is defined as an output DC voltage of 12V, a nominal capacity of 6Ah, and a discharge rate condition of 20hr. The specific meaning is: the battery pack with an output DC voltage of 12V is placed under a constant discharge rate of 20H for discharge until its output voltage drops from 12V to 10.5V. The total ampere-hours measured should be 6Ah.

Industrial batteries in my country, Japan, and Germany use a 10-hour rate (expressed as C10), and the US industrial battery standard is an 8-hour rate (expressed as C8,). In actual use, its discharge rate is not equal to the discharge rate specified by the standard capacity. When the actual discharge rate is greater than the discharge rate specified by the nominal capacity, its actual output capacity is less than the nominal capacity.

my country's power and postal standards stipulate that when a 10-hour rate battery is discharged at a 1-hour rate, its capacity is 55% of the nominal capacity, that is, 0.55C10. Japan's industrial standards stipulate that for a 2V/10-hour rate battery, the capacity is 0.65C10 at a 1-hour rate, and for a 6V, 12V, 10-hour rate battery, the capacity is 0.6C10 at a 1-hour rate. For a 20-hour rate battery, the capacity is 0.93C20 at a 10-hour rate and 0.56C20 at a 1-hour rate.

There are two ways to express the life of a battery: one is for a deep cycle battery, and the other is for a "backup power supply" battery used for floating charge. The service life of a deep cycle battery is expressed by the number of deep cycles. A battery used in a 0.8C10 deep charge and discharge cycle has a life of more than 1,200 times, while a battery used for floating charge can have a life of 10 to 20 years. The battery is considered to have terminated its life when it has only 80% of its capacity.

The actual service life is very different from the designed service life, which mainly depends on the loss of water in the battery. The design life can be achieved under the design conditions. However, when the external conditions such as temperature, charging voltage, and discharge depth exceed the design requirements, the actual service life will be much lower than the design life, and the actual use capacity will also be lower than the design capacity.

(2) The influence of discharge rate on the actual output capacity of the battery

The battery capacity C (Ah) is equal to the product of the discharge current (A) and the discharge time (h) when the battery voltage reaches the lower limit, while the discharge rate (1/h) is the ratio of the actual discharge current (A) to the nominal capacity of the battery (Ah).

In the actual operation of the UPS, after the mains power is cut off, the battery inverter is required to bear all the load power. The discharge rate varies greatly depending on the backup time. For example, the standard machine is about 10min, the maintenance time is very short, and the discharge rate is very large. The long-term machine can reach 4h or 8h, and the discharge rate is very small. Therefore, the actual discharge rate of the battery is not the discharge rate defined in the battery specification. The discharge curve shown in Figure 5-1 reflects the influence of different discharge rates on the battery capacity.

The smaller the actual discharge current of the battery, the longer the battery voltage can maintain stability, and vice versa. For example, for a 100HR battery pack, when the discharge current is 5A and the discharge rate is 0.05C, the output voltage is maintained above 12V for more than 10 hours. When the battery voltage drops to the critical voltage of 10.5V, the discharge time can reach 2Oh, and the capacity released by the battery is basically its nominal capacity. If the discharge current is increased to 100A and the discharge rate is 1C, the output voltage is maintained above 12V for less than 10 minutes. When the battery voltage drops to the critical voltage, the discharge time can be maintained for more than 30 minutes, and the actual released capacity is about 58.3.M, which is much lower than the nominal capacity of 100Ah.

The allowable discharge critical voltage value of the battery pack and the actual available capacity (AM) are closely related to the discharge current of the battery.

The allowable discharge time of the battery is the time taken for the battery voltage to drop from the rated value to the allowable critical voltage when the battery is discharged under the actual discharge current.

The available efficiency of the battery is the ratio of the actual maximum capacity it can release under the actual discharge current to its rated capacity.

It should be noted that under different discharge rates, the critical value of the battery terminal voltage drop is also changing. When the discharge rate is low, such as 0.01C, the actual released capacity is close to the nominal capacity, and the allowable battery terminal voltage drop is also high (10.5V). When the discharge rate is large, such as 1C, the actual released capacity is small, but the allowable battery terminal voltage can also be lower (8V).

Excessive high current discharge working mode is not favorable. When configuring batteries for UPS, it is not enough to configure the nominal capacity of the battery used based on the output current and battery power supply time required by the UPS during battery inversion. It is also necessary to appropriately increase the battery capacity according to the discharge rate during battery inversion and the output characteristics of the selected battery specifications.

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