AMCO Saft India Ltd

Ni Cd Battery
V/s
Lead Acid Battery
 Comparison (Electrochemistry)
Nickel Cadmium
Electrochemistry
The electrolyte is simply an ion carrier
and does not change chemically.
No noticeable change in electrolyte
density during charge / discharge
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Lead Acid
Electrolyte takes active part in
Chemical reaction
Aging starts the time electrolyte added
to the cell
Significant fall in electrolyte density
during discharge
Fall in electrolyte concentration results
in loss of conductivity & increase in
cell internal resistance
Electrolyte being active material, cell
voltage is affected by fall in electrolyte
concentration on discharge
 Comparison (Construction)
Nickel Cadmium
Electrode Design
Electrodes are held by nickel plated
steel frame providing mechanically
strong structure and good conductivity
All internal hardware (terminal post etc)
is Nickel plated steel.
Nickel plated steel is chemically inert to
alkaline electrolyte. No corrosion to
supporting / conducting structure for the
life time of the battery
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Lead Acid
Lead is used both as active material
and as support / current carrier
Lead is not totally inert to electrolyte
(H2SO4). Slow corrosion starts from
the moment electrolyte is poured in
cell. Corrosion rate aggravates at high
temperature, overcharge and eventual
structural collapse leading to –
RISK OF SUDDEN DEATH
 Comparison (Construction)

Nickel Cadmium Lead Acid

Electrode Design
Pocket plate construction enables to Not possible to produce thin grids
produce very thin plates for ultra high without sacrificing strength &
performance without losing mechanical conductivity
strength
Electrodes are strong to withstand
bumps / vibrations of mobile
applications and any severe seismic
condition

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 Comparison (Construction)
Nickel Cadmium
Pocket Plate
Active materials are retained in
perforated Nickel plated steel pockets.
Pockets prevents material from
shedding & bulging, also provides large
electric contact surface
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Lead Acid
No enveloping of active materials in
pasted plates (vented & VRLA) lead
acid. Tendency of electrodes to swell
and shedding of active mass.
Shedded actie material collects at
bottom of cell and possibility of this
touching plates thus creating a short
circuit. This leads to sudden death..
Tubular plates have soft & non-
conducting fabric enveloping
 Comparison (Construction)
Nickel Cadmium
Separator
Separation between electrodes is
provided by solid plastic grids
Large spacing between positive and
negative electrodes provides good
electrolyte circulation and gas
dissipation
Negligible ionic resistance.
Open space between electrodes does
not allow sludge accumulation or
dendrite formation
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Lead Acid
Apart from separating the electrodes,
the separator has to hold the active
mass
Separator design is very critical,
requires precise control of pore size &
pore size distribution to optimize
electrolyte absorption and ionic
resistance
Misbehaviour of separator leads to
loss of performance and battery failing
in a number of ways -
 Comparison (Construction)

Nickel Cadmium Lead Acid

Separator Misbehaviour of separator leads to
loss of performance and battery failing
in a number of ways -
Stratification of electrolyte in lead
acid battery
 Promotes dendrite formation
through pores leading to internal
short circuit
 Increases internal resistance due
to Formation of hot spots, sludge
deposit in pores
 causing thermal runaway in
starved electrolyte cells Gas
entrapped in separator affects high
rate discharge performance

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 Comparison (Construction)

Nickel Cadmium Lead Acid

Electrolyte
Aqueous solution of KOH of specific
gravity 1.2, optimised for life and
performance in wide temperature
ranges (-20OC to +60OC).
Dilute Sulphuric acid sp; gravity 1.2 to
1.3. Drastic Loss of ion mobility at
low temperatures, affects
performance. Electrolyte of vented
cells freezes below –10oC

Since electrolyte does not change Density decreases on discharge High

during charge / discharge, it retains rate performance is affected as
conductivity irrespective of state of discharge proceeds
charge.
A 50% discharged NiCad battery still Acid startification increases sulphation
has more than 80% high rate capability. & leads to capacity loss

No corrosive fumes. Corrosive acidic fumes evolves during

charging

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 Comparison (Construction)

Nickel Cadmium Lead Acid

Electrolyte
Lithium Hydroxide present in electrolyte Corrosion rate is increased at high
improves cycle life and high temperature
temperature performance

Sufficient quantity of electrolyte in cell Starved electrolyte in VRLA does not

for long topping up intervals.
Electrolyte does not change during
charge / discharge, it retains
conductivity irrespective of state of
charge.
assist heat transfer. Possibilities of
Hot spot formation & Thermal
Runaway
Electrochemical reaction as such, the
Sp. Gr changes over a period of time
which necessiates regular monitoring
of Sp Gr values.

Simple and rugged construction backed by a superior

electrochemistry make Ni Cad pocket - plate a
DIE HARD BATTERY
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 Comparison (Technical)
Nickel Cadmium
Charging
Rapid recharge possible
90% SOC achieved in 8 - 12 hrs
Boost welcomed
No problem with overcharge
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Lead Acid
No rapid recharge
48 - 100 hrs for regaining 80% SOC for
VRLA
Rapid charge increases H2 gassing up to
explosion for VRLA
Float charger setting with narrow voltage
tolerances
Float charger setting to be changed with
battery age
Temp. compensation compulsory (-5.5
mV/cell per increasing oC) for VRLA
Boost charging increases shedding of
positive active mass
Overcharge increases grid corrosion and
dendrite formation
 Comparison (Technical)
Nickel Cadmium
Charging
15% AC ripple current acceptable
High Rate Discharge
Rate of 10 to 20 C5 is possible.
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Lead Acid
Overcharge of VRLA causes evolution
of gases resulting in capacity loss and
life reduction.
High ripple current increases grid
corrosion.
Ripple current which is very critical in
VRLA increases internal heat and
thermal runaway.
Thick plate construction does not
allow high rate discharge.
If there is excessive corrosion,
remaining alloy can melt causing open
circuit and explosion..
 Comparison (Technical)

Nickel Cadmium Lead Acid

Deep Discharge
No problems with Deep discharge.
Can be fully discharged. Even
reversed cell after charging is healthy
to use.
Immediate recharge is compulsory to
avoid sulphation.
Discharge below 60% is NOT
recommended.
Deep discharge leads to large evolution
of gases, causing capacity loss and life
reduction in case of VRLA.
In case VRLA cell if fully discharged,
needs replacement.

High Temperature Increase grid corrosion and shedding.

Marginal fall in life. Risk of thermal runaway
For every 8 – 10o C rise in temperature
above 25o C, life of VRLA reduces to
Half.

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 Comparison (Technical)

Nickel Cadmium Lead Acid

Operating Life
Normal life of 3-5 Yrs in VRLA, 5-8 Yrs
Exceeds 20 years in Tubular & 10 Yrs in Plante.
More than 1500 life cycles.

Maintenance
Topping up once OR twice a year
No Topping up for VRLA
required.
Each cell voltage, Sp gravity and
electrolyte level has to be monitored..
Cells with variation more than 0.02 V
to be isolated
Since evolved gas has acidic content,
terminal corrosion occurs faster which
needs frequent cleaning.

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 Comparison (Technical)

Nickel Cadmium Lead Acid

Maintenance

Boost charging once in a year. Float charging setting to be corrected

with change in ambient temperature
for VRLA
Full charge and discharge cycle to be
carried out to ensure stirring of
electrolyte at least twice in a year.

Storage
Ni Cad batteries can be stored in any Batteries should not be stored, off
state. Either Charged OR discharged, charge for more than 6 months
even partial discharged also for any
length of time.

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 Comparison (Technical)

Nickel Cadmium Lead Acid

Capacity Range
.
62 ratings from 11 – 1450 AH 39 ratings starting 20 to 5000 AH
This gives an opportunity to do an
optimum sizing.

Weight

For a 100 AH cell weighs approx 6.5 Kg For the same 100 AH, tubular cell
with electrolyte. Just to compare a 110V weighs 11.1 Kg and Plante weighs 21
DC system, total number of cells will be Kg resulting in total battery weight of
87 and battery weight will be approx 611 Kg and 1100 Kg.respectively.
550 Kg.
AH requirement for given load is
approximately 30 - 35% lower resulting
in considerable weight reduction

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 Comparison (Technical)

Nickel Cadmium Lead Acid

Battery Room

Anti alkali tiles cost less than acid proof Requires expensive acid proof tiling.
tiles.
Low gassing, therefor less ventilation Gassing being more requires more
required.
ventilation
Battery weight is 50% of Plante, hence
flooring to be designed for lighter loads.
Smaller foot print of stand calls for
smaller battery room.
On account of above, cost of battery
On account of above cost of battery
room is lower.
room is higher

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 Advantages (Technical)
SPECIFIC ADVANTAGES OF NICKEL CADMIUM OVER PLANTE
• The plate (steel construction with nickel plating) having the active materials
nickel hydroxide and cadmium hydroxide) are of sturdy and stable construction,
as such during charge-discharge cycle, the plates are not affected by the stress
and strains to which they are subjected.

• The electrolyte is chemically inert not taking part in the electrochemical

reaction giving considerable advantages in respect of evolution of gases,
specific gravity remains constant through out battery life.

• A critical advantage of nickel cadmium is that the phenomenon of sudden death

often encountered in Tubular/ VRLA or Plante lead acid batteries does not occur
in nickel cadmium, thus conferring on nickel cadmium batteries – RELIABILITY.

• In view of its robust construction nickel cadmium can withstand mechanical and
electrical abuse without affecting the operational efficiency of the battery.

• Nickel Cadmium batteries lower weight and volume than Plante batteries
therefore cost incurred in the construction and maintenance of the battery room
is substantially less than compared to Plante batteries.

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 THANK YOU

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