TECHNICAL BULLETIN FOR BULGING ON VRLA BATTERIES & RELEASE OF

EXCESS GASES IN REPLACEMENT CELLS.

Ref. REC / APE IBD/BUL/VER-0/006/08-09
Page 1 of 2

LEAD ACID BATTERY:

The lead acid storage battery has been used as a source of secondary DC power for ages. Known for its
reliability and economic viability, the lead acid system has maintained its edge over other electro-chemical
couples.

THEORY

The electrochemical device which uses lead and its derivatives and sulphuric acid as its constituents is
called a Lead Acid Battery. Any battery consists of positive plate (Anode), a negative plate (cathode) and
electrolyte. In a lead acid battery, the positive plate consists of an active material lead dioxide (Pbo2) and a
grid structure of either pure lead or lead alloys which acts as a supporting structure as well as current
carrying conductor. Similarly the negative plate consists of spongy lead (Pb) as active material and pure
lead or lead alloy for the grid structure.The electrolyte used in a lead acid battery is diluted sulphuric acid.

The basic reaction that is taking place in a lead acid battery is given by the following equation.

Pbo2 + Pb + 2 H2SO4 Discharge Pbso4 + PbSO4 + 2H2O

(+ve plate) (-ve plate) Charge (+ve plate) (-ve plate)

From the above equation it can be seen that the reaction is reversible and based on which the lead acid
battery is classified as secondary battery which can give a number of discharge and charge cycle. During
discharge, the lead dioxide in positive plate and spongy lead in negative plate react with sulfuric acid in the
electrolyte to form lead sulfate both in positive and negative plate and water in the electrolyte. The
chemical reactions for the same are shown below.

TYPES OF LEAD ACID BATTERIES

There are two types of lead acid batteries namely,

Flooded Lead Acid Battery and

Sealed or Valve regulated lead acid battery( VRLA)

FLOODED LEAD ACID BATTERY

In this kind of battery, the acid is in free condition and during at the end of charging oxygen and hydrogen
liberated due to decomposition of water will escape from the electrolyte. The battery therefore needs to be
replenished with water regularly. This required maintenance poses problem in the usage of these batteries.

VALVE REGULATED LEAD ACID BATTERY

The electrode reactions in VRLA battery are in principle same as in the case of flooded lead acid battery. On
the other hand at the end of charging, oxygen liberation at the positive plate occurs before hydrogen evolution
of the negative plate. This feature is utilized in the design of VRLA batteries. The oxygen gas evolved at the
positive plate is transported to the negative plate and gets recombined.
The separator is typically absorbent glass mat (AGM) type and designed to have pore volume in excess of the
electrode volume due to which the oxygen gas finds an unrestricted path to the negative plate. The reaction
reduces the oxygen gas with the spongy lead at the negative plate turning a part of it into partially discharged
condition, thereby effectively suppressing evolution of hydrogen gas. This phenomenon is known as Oxygen
recombination.

Proprietary Material of M/s. AMARA RAJA BATTERIES LTD., Tirupati.

All rights reserved. No copying Permitted. Unauthorised use Prohibited.
Prepared and Issued by REC/IBD-Application Engg.
TECHNICAL BULLETIN FOR BULGING ON VRLA BATTERIES & RELEASE OF
EXCESS GASES IN REPLACEMENT CELLS.
Ref. REC / APE IBD/BUL/VER-0/006/08-09
Page 1 of 2

This Oxygen recombination will takes place under positive pressure and as per cell design the positive
pressure is allowed from 4 to 6 PSI. If we reduce the positive pressure in the cell resulting in reduction of
oxygen recombination efficiency there by resulting in water loss. When cells are operating at positive pressure
some cells will release the gas at 4 PSI & some will be at 6 PSI. The cells where releasing at 6 PSI will have
little cell bulging and it will be visible due to material (PPCP) characteristic. This bulging will not have any
disadvantage / issue related to batteries and it is natural phenomena for VRLA batteries.

PROCEDURE FOR RELEASING OF EXCESS GAS:

If we observe bulging / excess gases in replacement cells (packed in single cell box) before inserting in to the
MS trays, please rotate the vent cap (with appropriate tool) in anti-clock wise direction for an half a round to
release the excess gas. Then insert cell in the specified MS trays and rotate the vent plug in clock wise
direction half a round (with appropriate tool) to close the vent cap.

End of the report

Proprietary Material of M/s. AMARA RAJA BATTERIES LTD., Tirupati.

All rights reserved. No copying Permitted. Unauthorised use Prohibited.
Prepared and Issued by REC/IBD-Application Engg.