HOW IT IS MADE : The Lead Acid Battery Part – 4

All production processes need the correct amount of lead oxide. This makes sure the active material will work in the lead acid battery. After producing the oxide, researchers carefully turn it into the chemical compound needed for the grids. They must carefully measure the components with precision and thoroughly mix them in the correct proportions in order to ensure the highest level of accuracy during this crucial step.

Sovema uses the Shimadzu method to produce Lead oxide. This method involves two key steps. First, a surface undergoes oxidation, which involves exposing the metal to oxygen so that it reacts and forms a protective layer of oxide. Subsequently, the process removes the powder that forms as a result of this reaction. This step is essential because it clears the surface and exposes fresh metal underneath. Once exposed, the new metal is then ready to oxidize again in the same manner, allowing the cycle to repeat continuously.

The basic parameters of this process are as follows:

• Surface
• Temperature: the catalyst element of production
• Oxygen: an essential element for the oxidation process
• Mass of lead components: provides the mechanical stress to remove the oxide. The greater the mass, the greater the power of removal. The smaller the size of the piece, the higher the amount of surface per unit of weight.

Making the paste

The production department comprises several key production systems, including the following:

• Production of pieces to be used
• Oxide production machine
• Oxide separation filter
• Oxide transport and storage systems

There are two systems to produce single pieces of lead:

1. Production through casting and solidification (thermal system);
2. Production  of  cubes  through  a  mechanical shape changing system.

Thermal system in Lead Oxide

With this system, the lead melts as it is pumped or spread into the cylindrical cavity. This cavity has equal sides, meaning its height is the same as its diameter. The dimensions must be about 20 mm.

Components needed:

• Pot
• Pump
• Cylinder casting machine

The machine pumps the hot, melted lead oxide into a rotating carousel. This carousel holds a series of cool moulds. The lead is poured into these moulds. The carousel spins at a steady speed and stays at a set temperature. This steady movement gives the lead time to cool down into solid cylinders.

At the end of the rotation, a mechanical system ejects the materials from their housing. Specifically, this system pushes out solid lead oxide volumes that are ideal for the oxidation process. In addition, it creates space for new materials to enter, ensuring continuous operation. However, despite its functionality, this machine has low energy efficiency levels and is at a high risk of contributing to environmental pollution. Furthermore, it necessitates the manual assistance of an operator to ensure smooth and accurate operation.

Mechanical system

The mechanical system consists of a lead ingot loader, a slicer and a moulding system. The ingots are first cut into 18mm slices. Then, they go to the moulding system. This system divides the slices into many small cubes. The system only uses energy to change the shape of the ingots. Due to this optimization, the overall energy efficiency significantly improves. As a result, the process generates almost no pollution, making it highly environmentally friendly. Moreover, the only manual intervention required is during the ingot loading stage.

At this stage, the material is carefully placed into a hopper, which then serves as a feeder for the plant. Additionally, a vibrating conveyor system is responsible for transporting the material out of the hopper. This process is triggered automatically whenever the system detects that it is necessary. Specifically, the system continuously monitors the amount of material inside the mill’s drum in order to determine the optimal time for extraction, ensuring smooth and efficient operation.

Oxide production mill

The machine rotates several cylinders or cubes produced as described above. The mechanical stress generated by the engine produces a temperature increase inside the mass of the cubes, bringing the material close to the operating temperature. Under these conditions, oxygen is added to the lead surface. This causes a chemical reaction called oxidation. The oxidation reaction produces heat. To manage the heat and prevent overheating, operators closely monitor the temperature. Special cooling systems actively control the temperature. Afterward, they form an environment rich in oxygen. This atmosphere creates a layer of oxide powder on the surfaces of the cylinders.

The rotating drum generates friction among the cylinders, which, in turn, gradually leads to the removal of the oxide powder from the surfaces. As a result, this action continuously creates new areas for oxidation to take place. Furthermore, the process remains active as long as there is solid material present inside the drum, thereby ensuring a continuous cycle of oxidation and renewal. In order to further enhance the efficiency of the process, it is essential that each piece inside the drum has all of its surfaces fully exposed to the oxidation environment.

This means every part of the pieces needs to come into contact with the surroundings within the drum. This means the pieces should not stick together. This way, they can rub against each other completely. As a result, the most suitable shape is a sphere. This is achieved by loading the drum with equilateral cylinders or cubes. The physical form of the oxide, given the production on surfaces, will be of the lamellar type and, consequently, of maximum surface per unit of volume. Its responsiveness will be very high.

Barton Method in Lead Oxide

This is different from the Barton method. In the Barton method, It forms through the spreading of tiny drops of liquid. These drops then turn into small spheres. The spheres have a small surface area compared to their volume. In this case, the responsiveness is very low.

The operators will control the mill. They will adjust the temperature during the process. They will also monitor how much material is inside the mill. Another task is to manage the airflow that goes through the mill. Lastly, they will control how fast the mill rotates. The machine will provide a lead powder  oxidised  at  70-75%,  therefore containing a quantity of metallic lead in micrometric  dimensions  equal  to  30-25%.  At this stage, the airflow passing through the drum removes and transports the oxide powder, conveying it into the powder separation filter to detach it from the air.

Filter

The filter plays a crucial role in separating the lead oxide powders from the air that transports them. Specifically, it consists of two or three sections and operates at approximately 120°C in order to prevent the oxidation of the lead that remains free during the production stage. Furthermore, this component undergoes significant mechanical stress, primarily because the sleeves move extensively during the washing process. Additionally, the filter is designed with two distinct filtration sections to enhance its efficiency and durability.

The first part of the filtration process relies on needle-punched felt sleeves. However, to ensure their efficiency, a specialized air-powered system regularly cleans them. (Pneumatic refers to a system that operates using air.) Notably, this system is responsible for handling 99% of the filtering work. Subsequently, the air passes through specially designed cardboard packs made from glass fibers, which effectively remove 99.999% of the remaining material. This final stage, known as absolute filtration, ensures maximum purification. Moreover, the information required to control the entire filter system is derived from this setup. Additionally, a mechanical unloading system efficiently transports the lead oxide collected in the filter hopper to the subsequent conveyors, which then carry it to the designated storage system.

Lead Oxide Storage Silo

The storage plant to contain the oxide consists of a variable set of silos equipped with a weighing system for checking the filling state of the machine and an inlet/outlet air device. A vibrating bottom helps both of these systems. The vibration helps remove the oxide. Lead Oxide is a type of chemical compound. The resulting oxide will need two days to balance the oxidation level of the material contained in it.

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Amol Khodre Web Developer

A driven and dedicated IT professional specializing in web development, search engine optimization (SEO), and digital content creation. Backed by a strong academic foundation and extensive hands-on experience at Coneixement INDIA, I consistently deliver innovative, high-quality digital solutions that enhance user experience and drive measurable business growth.

With a passion for continuous learning and advancing my technical expertise, I am eager to take on new challenges in dynamic, larger organizations where I can contribute to transformative projects, optimize digital strategies at scale, and help elevate the company’s online presence. My commitment to excellence, combined with a results-oriented approach, makes me a valuable asset ready to support business objectives and future-proof digital initiatives in competitive markets.

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