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ERA Technology Limited

Cleeve Road Leatherhead
Surrey KT22 7SA England
Tel: +44 (0) 1372 367000
Fax: +44 (0) 1372 367099
E-mai l : mf@era.co.uk
Internet: http://www.era.co.uk/
TECHNO
PRODUCT ASSESSMENT DMSION
FINAL REPORT
ERA Report 98-0480
ERA Project 42-01-4734
Published
Client : Mr A Green
Client Reference : IBG/MKT/AG/042/96
Report Approved by:
N A Adatia
Director of Technology
May 1998
Ref. 57-R58 19/42/MLW/JCM
R E S E AR C H, DE VE L OP ME NT A N D T E S T I NG F O R I NDUS T R Y - WO R L D WI D E
CIGECTORS A W Rudqn CBE FEng FA5 PhD FIEE ( Cha~mdnl M J Wtrners MSc FEng FIE I Md n a g q l Str D a d Dav~es CBE FEng FRS C P N Fert s VA MSA Dl pM XMA
K %dqwick FCMA FCCA JD7pMA R W E Shannon BSc PhD FEnq HonOSc HonDTech FlMechE FlGasE MFWeS M T Wr qhl BSc PhD FEng FlEE FI MemE
k s m d l e C~t er l or s N A Adabd a% PnD CEng FIE A G Carr BSc FhD CEng FlEE J E Fewrreil FCMA iConiparv c%cra:arll hr W,lllarns BEng PhD DIC CEng MIEE
t CP me d tc 35 EN I S0 9001 1W.l Rag k s FM1303 and FMZ7079 C c mp r q reg6tered ~n E n g a d No 1704% Regstered o l i m as a t me
This report compares and contrasts the general features of vented (flooded) and valve regulated (sealed)
lead-acid and nickel cadmum batteries. In particular, the electrochemistry of these batteries is
dscussed with regard to the practical implications on design, cost and manufacturing procedures. The
relative performances are compared, and an evaluation is made of the strengths and weaknesses and
their applications are briefly dscussed.
Lead-acid batteries are relatively inexpensive, but lead metal, the main structural component for the
plate groups and whch forms the active material for the negative electrode, is not totally stable in the
sulphuric acid electrolyte. l h s results in corrosion and eventual structural failure and also self
dscharge of the negative plate. If the active materials are left in a dscharged condtion the lead
sulphate discharge product becomes converted to an irreversible form resulting in permanent loss of
capacity. Unless adequate precautions are taken valve regulated designs may suffer from increased
corrosion of the positive plate grids and negative group bars. Moreover, the hydrogen gas associated
with the self-hscharge may result in an accelerated loss of capacity and drying-out of the electrolyte.
Nickel-cadmium battery materials are more stable in the electrolyte and remain in a rechargeable form
even ~vhen stored for a prolonged period in a discharged state. Structural failure as a consequence of
corrosion is usually negligible and the service life is generally greater than that of lead-acid batteries.
Ho~vever, the variable oxidation state and morphology of the active materials and the 'floating.effect' on
prolonged float charge can result in a reduction of the performance of emergency standby batteries.
This effect has to be compensated for by increasing the battery size. Operation at high and low
tcmpcratures is more feasible than for lead-acid designs, but extended sewice at excessively hgh
tempcratures will rcsult in reduced lifetimes.
The choice bctwccn large lead-acid and nickel-cadmium industrial batteries for any particular
application will depend on a combination of compliance with technical requirements and price.
Compared with nickel-cadmium products, the main t e c hc a l limitation of the Icad-acid batteries are
their pcrformance at Ion temperatures, reduced life at high temperatures and the permanent loss of
capacity resulting from incomplete charging. Ttus places limitations on their use In applications ~vhere
exposure to low or high temperatures can occur and in applications such as solar power where the
batten. may not be fully charged for an appreciable length of time. Valve regulated cells have other
disadvantages such as the drying-out and corrosion of the group bars which can be pronounced at
elevated temperatures and can result in rapid and unexpected loss of performance. On a cost per
ampere-hour basis, ni ckel -cahum batteries are approximately double the price of lead-acid
equivalents and thls increases to around threefold when the voltage dfference is taken into account. An
important 'factor in mitigation is the superior power output of ni ckel - cahum and the smaller cell size
necessary for hgh power applications whch results in a lower cost.
Generally, lead-acid batteries are preferred for the majority of applications where abusive operating
conditions can be avoided largely because of their lower first cost. However, where extremes of
temperature, undercharging, overcharging and mechanical abuse are possible a nickel-cadrmum battery
is 11kely to prove to be the most cost effective option overall.