AMCO Saft India Ltd

WELCOMES
Power Development Board
Dhaka, Bangladesh
On Nickel Cadmium Battery
Product Presentation
 AGENDA
1. Company Overview &
Manufacturing Facility In India
2. Pocket Plate Technology &
Construction
3. Battery Characteristics
4. Comparison of Batteries
5. Open Session
-------------
AMCO Saft India Ltd

Company Overview &

Manufacturing Facility
In India
 Overview

• The Saft group, a global multi technology battery specialists with

a leadership position in its chosen markets.

• Committed as ever to pursuing the win-win partnership with industry it

has developed over the past 100 years.

• Saft’s 4000 dedicated employees are deployed in

18 countries around the world.

• More than 350 research and development staff.

• 35 Million Euros R&D budget

• Saft is a pioneer in battery R&D creating new technologies and

optimising existing technologies for future applications

4
 Overview
manufacturer of Ni-Cd batteries
N°1 For industrial use in transport, stationary
applications and security lighting

manufacturer of primary Lithium

N°1 Batteries
For both military and Industrial
applications

manufacturer of specialised batteries

N°2 For defence and space applications
(N°1 in Europe)

Industrial Nicad, Aviation batteries,

Products Satellite batteries, Torpedo batteries,
Primary & secondary Lithium batteries, NiMH
& others
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 Overview
BESS - the world’s most powerful battery

• BESS - Battery Energy Storage System

• Battery back-up for the city of Fairbanks in Alaska, up to fifteen minutes
back-up if the normal power supply is not working
• Capacity - 27 MW / 15 min
• 13760 cells SBH920 (920 Ah)
• System fact
- voltage 5000 Volt
- Capacity 3680 Ah (ampere hours)
- weight ~1000 tons
- service life at least 20 years
• Delivered in 67 containers
• Recorded in Guinness book of record

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 Overview

Position : largest manufacturer of Batteries in

the world

Experience : Inventor of nickel-cadmium

batteries

Expertise : Pocket, sintered, and plastic

bonded plate technologies

Brands : SAFT, ALCAD, NIFE, FRIWO,

EMISA, FERAK, CENTRA, AMCO SAFT

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 Overview

• Saft and Amco Power Systems Ltd joined forces to create AMCO Saft India Ltd,
Web Site at www.amcosaft.in

• Majority share holding by Saft, France. Web Site at www.saftbatteries.com

• Our employees have been trained to understand your needs and to engineer the
most optimised battery solution, ensure delivery and installation to your
satisfaction and provide after sales.

• AMCO Saft India Ltd can now supply Ni-Cd and other alkaline batteries, primary
and secondary Lithium batteries and silver based technology batteries.

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 Markets Served Today
Professional Electronics
Aviation & Security Systems

Building & Rail & Mass Transit

Industrial Plants

Road Transportation
Defence
& Infrastructure

Emergency Space
Lighting

Medical Telecommunication

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 Overview (History)

1899 - First patent for alkaline battery

1900 - Foundation of Nife
1918 - Foundation of Saft

1990 - AMCO started Nicad production in

technical colaboration in India

1991 - Merger of Saft with Nife

2006 - Equity participation by Saft &

formation of AMCO SAFT INDIA LTD (ASIL)

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 Overview (Manufacturing Facility)

• Nicad manufacturing facility at BANGALORE being up-graded to meet

SAFT GLOBAL STANDARDS, in terms of
•Productivity to Saft World Class Programme
•Product performance
•Safts proven Quality Systems

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 Overview (Manufacturing Facility)

• Capacity increase to meet growing demands & for quicker deliveries.

• Introducing New ULM Nicad products conforming IEC 62259

• Starting production of Aviation & Sintered -Plastic bonded Nicad

• Introducing high tech products based upon Lithium & Silver electrochemistry

• Quality audits by Saft

• Training ASIL personnel in technology & application engineering & software tools
for battery selection.

• Design improvements for high temperature ambient

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 Overview (Sector, Application & Major Customers)

Sector : Oil Exploration & Petroleum Pipe lines, Refinery /

Petrochemical, Power, Fertilizer / Chemicals, Steel,
Metals, Mines, UPS, Process Control, Telecom,….

Application : Inst & Control, Emergency Lighting, Gen Set Starting,

Fire Alarms, Fire Pumps, Compression Units, Gas
Turbine, Navigation, Electromagnetic Cranes, Captive
Power plants, ….

Major Customers : GAIL, Oil India, ONGC, L & T, NTPC,

Hindustan Shipyard, Visakhapatnam, IOCL, IPCL,
HPCL, BHEL, ABB, Yokogawa Blue Star, Honey Well
Limited, Hi-Rel Electronics, DB Power Electronics,
DMRC, CLW, DLW,….

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 AMCO Saft India Ltd

Ni Cad Battery Types,

Pocket Plate Technology &
Construction
 Electrochemistry
• In all types of Nickel Cadmium cells the active constituents are Cadmium in the
negative electrodes & Nickel in positive electrodes.
• The electrolyte is a solution of Potassium hydroxide in deionised water. The
constituent parts of positive/ negative electrodes & passive components i.e. plate
lugs, terminal etc are insoluble in electrolyte.
The simplified overall reversible electrochemical reaction given below which
produces a nominal discharge voltage of 1.2 volts per cell.

Charge
2Ni(OH)
  2 + Cd(OH) 2 2NiOOH + Cd + 2H2O.
Discharge

When the cell is charged, the Cadmium hydroxide is reduced to Cadmium and
Nickel hydroxide attains a higher degree of oxidation. On discharge, the process is
a reversed and the active materials revert to their original state.
The potassium hydroxide electrolyte doesn’t take part in these reactions and
acts only as a carrier of ions.

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 Electrochemistry

Thus, through its electrochemistry, the Nickel Cadmium battery has

• Stable behaviour

• Long Life

• Excellent Characteristics

• A high resistance against abusive conditions

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 Ni Cad Battery Types

Nicad Batteries

Pocket Sintered Plastic bonded Ni foam/Fibre

plate plate plate plate

• Vented cells - plastic (PP or SAN) or steel prismatic cases

• Valve regulated low maintenance cells - plastic prismatic cases
• Sealed cells - cylindrical steel cases

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 Ni Cad Battery
Pocket plate
Construction Features

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 Construction Features (Plate Assembly)

• Active materials (Nickel Hydroxide for Positive and Cadmium Hydroide for
Negative) are retained in perforated Nickel plated steel pockets. This
Prevents material from shedding and bulging.

• Electrodes are held by nickel plated

steel frame providing mechanically strong structure

and good conductivity.

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 Construction Features (Plate Assembly)

• Electrodes of same polarity are grouped

together by bolting, using nickel plated steel
fasteners.

• Nickel plated steel is chemically inert to alkaline

electrolyte. No corrosion to supporting /
conducting structure for the life time of the
battery.

• Electrodes are strong to withstand bumps /

vibrations of mobile applications and any severe
seismic condition. Additives in negative active
material of pocket plate NiCad batteries
eliminate memory effect.

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 Construction Features (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.

• Non porous surface does not result in dendrite

formation.

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 Construction Features (Electrolyte)

• Aqueous solution of KOH of specific gravity 1.2, optimised for life and
performance in wide temperature ranges (-20OC to +60OC).

• Since electrolyte does not change during charge / discharge, it retains

conductivity irrespective of state of charge.
– A 50% discharged NiCad battery still has more than 80% high rate
capability.

• No corrosive fumes.

• Lithium Hydroxide present in electrolyte improves cycle life and high

temperature performance

• Sufficient quantity of electrolyte in cell for long topping up intervals.

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 Construction Features (Terminals)

• Nickel plated steel terminals of ample cross

section to withstand high currents.
Mechanically strong and corrosion resistant
(No sulphation).

• Bolted construction for ease of inter cell

connections.

• Alkali resistant rubber gasket provide

satisfactory sealing between terminal and
cover for the life of battery.

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 Construction Features (Vent Plug)

• Flip - top vent for ease of operation.

Topping up can be done without removing it.

• Flame arresting feature - a safety against accidental external sparks.

Lid
Flame Retardant Disc
Spring

Flip

Flip Gland
Hinge Pin
Seating Washer
Body

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 Construction Features (Container)

• High Impact resistant polypropylene container.

• Heat sealing for reliable welding

• Transluscent cell container for visibilty of

electrolyte level

• Complete freedom from corrosion in wet and

saline atmosphere

• Highly insulated material of polypropylene cell

container. No need for additional insulation. Can
be installed directly on steel racks without
insulation cell case and stand surface.

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 Construction Features (Connections)
Inter Cell
• High conductivity copper designed to withstand
short circuit current
• Nickel plating for corrosion resistance (no
sulphation)
• PVC shroudings over connectors provides
insulation cover
• In case of parallel battery bank individual cells
are parallely connected

Battery Stand
• Mild steel angular or tubular structure
• Modular design for 2 to 4 steps, single & double
tiers to suit any space requirements
• Alkali resistant painting
• Bolted construction for ease of installation

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AMCO Saft India Ltd

Ni Cd Battery
Characteristics
 Battery Characteristics
CELL CAPACITY

• In absolute terms it is capacity of cell to store charge (coulombs) by

electrochemical conversion of active masses in positive & negative electrodes.
• 1 Ampere hour (AH) = 3600 coulombs. Cells are normally designed with excess
negative capacity, hence cell capacity depends upon the quantity of positive
active mass in cell.
• There is no simple method to test absolute capacity,because capacity on
discharge depends on end cell voltage, discharge current & temperature. Some charge
also gets self discharged during testing.RATED CAPACITY (C5) : It is capacity of cell
in AH when tested under defined conditions as per standards. Nicad capacity is
normally defined for 5 Hrs discharge.

IS - 10918 IEC - 60623

TEMPERATURE 27oC 20oC
CHARGING 0.2C5 for 7 to 8 Hrs, as per manufacturer,s instructions
REST 16 to 24 Hrs 1 to 4 Hrs
DISCHARGE Discharge current = 0.2C5, End cell voltage = 1.00v

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 Battery Characteristics
Though the cell capacity depends upon total quantity of active mass, the high rate
performance depends upon surface area of electrodes and open space between
electrodes.High rate performance of cell is improved by distributing active mass in
more number of thin electrodes.
KL KM KH KX

• Active Material / Ah (Ratio) 1 1 1 1

• Ratio of Plate No. for same 2 3 5 7
capacity
• Plate thickness (mm) 3.7 3.0 2.0 1.2
• Internal Resistance () 0.25/C5 0.15/C5 0.07/C5 0.05/C5
• Nominal Capacity 100 Ah Cell 100 100 100 100
5 hr to 1.0 V
• Available Capacity 30 min. to 37 % 49 % 71 % 79 %
1.1 V
• High rate Current for 1 sec. to 470 A 878 A 1600 A 2100 A
0.65 V 100 Ah Cell

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 Battery Characteristics

Discharge Characteristics - KL & KM

1.4

1.3

1.2
CELL VOLTAGE (V)

1.1

0.9 KL 0.2C
KL 1C
0.8
KM 0.2C
0.7 KM 1C
KM 2C
0.6
0 10 20 30 40 50 60 70 80 90 100 110
CAPACITY (AH)

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 Battery Characteristics
Cell capacity decided by :
• Load current
• Stand by period
• End cell voltage
• Cell type

Useful Capacity – H type Useful Capacity – L type

100
100
80
80

60 60

40 40

20 20

0 0
30 Mts 1 Hr 5 Hr 30 Mts 1 Hr 5 Hr
ECV : 1.14 1.1 1.05 1
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 Battery Charging

32
 Battery Characteristics (Charging)
CHARGING CHARACTERISTICS AT 0.2C5 RATE

1.9

1.8
CELL VOLTAGE (V)

1.7

1.6

KL
1.5
KM
1.4 KH
KX
1.3
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
CHARGED CAPACITY (%C5)

Charging voltage KL > KM > KH

KX behavior different due to different plate type.
Low voltage till 90% SOC, then increases rapidly .

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 Battery Characteristics (Charging)
Effect of Charging Rate

Charging voltage increases with increase in charging rate.

Effect of charging rate ( 0.1C5 to 0.3C5) on KM cell shown below :

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 Battery Characteristics (Charging)
Efficiency

AH efficiency is good at early state of charge (85% on 100% AH input)

Efficiency falls at higher SOC, as more charge is used in gas formation.
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Available Capacity
100
90
80
70
60
%

50
40
30
20
10
Charge Efficiency
0
0 20 40 60 80 100 120 140 160
CHARGED CAPACITY (%)

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 Battery Characteristics (Charging)
Constant Current (CC) Charging :

Constant current charging ensures 100% state of charge.

Normally used for battery testing, commissioning or maintenance. Rarely used in
service.
By charging more than 140% of rated AH capacity, cell can be fully charged.

Normal charging : 0.2C5 Amps for 8 Hrs

Maximum charging rate :

KL 0.3C5 A

KM 0.3C5 A

KH 0.5C5 A

High rate charging to be avoided at the end of charging, as there is a risk of

electrolyte overflow due to heavy gassing.

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 Battery Characteristics (Charging)
Constant Potential (CP) Charging :

• Constant potential charging with current limiting to 0.1C 5 A to 0.3C5 A is the

most common way of charging in service.

• Charging voltage should be more than the open circuit of fully charged cell but
less than the end of charge voltage on CC charging (1.39V to 1.7 V per cell).

• On charging battery voltage increases & voltage gradient between battery &
charger decreases, leading to fall in current. A lower charging current at the
end of charge automatically controls gassing.

• It takes much longer time to attain 100% state of charge. At low charge
voltages (<1.5 vpc) full state of charge is never reached.

• Constant potential is the only practical way of charging standby batteries for
float applications.

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 Battery Characteristics (Charging)
Constant potential charging of KM cell with current limit 0.2C5 Amps
1.65
CELL VOLTAGE (V)

1.6
1.55 CELL VOLTAGE VS TIME
1.5
1.45
1.4 1.45 V/Cell
1.35 1.6 V/Cell
1.3

0.24 120
CURRENT & AVAILABLE CAPACITY VS TIME

AVAILABLE CAPACITY (%)

0.2
CURRENT I/C ( Amps)

100

0.16 80

0.12 CURRENT 1.45 V/Cell 60

CURRENT 1.60 V/Cell
0.08 CAPACITY 1.45 V/Cell
40
CAPACITY 1.60 V/Cell

0.04 20

0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
TIME (Hrs)

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 Battery Characteristics (Charging)
Float cum Boost Charging :
Cells are normally on float charge at the following voltages
KL, KM, KH - 1.40 to 1.42 Volt/ cell
Minimum 2mA per AH current required to compensate for self discharge.
Negligible water loss on float but require boost charging at 12 monthly intervals &
after discharge. Cells to be Boost charged at following voltage:

KL - 1.50 to 1.65 Volt/ cell

KM, KH - 1.47 to 1.62 Volt/ cell
• It is preferred to boost at 1.52 to 1.57 Volt/ cell. More than 95% capacity can be
restored within 8 hrs after emergency discharge.
• It is safe voltage. Excess boosting duration, won’t damage the cells.
• A significant fall of current is indication that battery is more than 95% charged &
can be switched to float.
• Prolonged boost charging at >1.57 vpc can overcharge battery leading to
excess water losses. Few days of over charge can dry the cell & damage it.
• Due to voltage window restrictions or charger’s limitation batteries can be
boosted at low voltages (1.45 to 1.50 vpc). Batteries in such cases can be
recharged to 85 to 90% capacity ..

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 Battery Characteristics (Charging)
Single stage charging
For fully automatic operation cells are floated at higher voltages. Periodic boosting
or boost charging after emergency discharge is not required.
Recommended voltages for single stage float charging are :
KL - 1.48 to 1.60 Volt/ cell (preferred 1.48 to 1.51)
KM - 1.47 to 1.57 Volt/ cell (preferred 1.47 to 1.50)
KH - 1.45 to 1.53 Volt/ cell (preferred 1.46 to 1.50)
All type of cells for starting application - 1.50 to 1.55 Volt / cell
More than 80 % capacity can be restored within 5 hrs after emergency discharge.
Depending upon float voltage cells can achieve 90 to 98% state of charge in 24 hrs.
Water losses are higher than in case of float cum boost charging.

Commissioning charge / Service boost charging

Battery is required to attain 100% state of charge for commissioning, testing &
maintenance(cell changing). This can be ensured by constant current charging
only. To maintain constant current minimum voltage should be 1.72,1.70 & 1.68 vpc
respectively for KL,KM & KH/KX. If charger voltage is inadequate, battery is split
into two banks and charged.

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 Battery Characteristics (Charging)
Cell Voltage
Nominal voltage of Nicad cell is 1.2V

DISCHARGE
CONSTANT CURRENT( 0.2C5 A) CHARGE

GASSING REGION
OPEN CIRCUIT VOLTAGE (Charged cell)

CONSTANT POTENTIAL CHARGE FLOAT BOOST

SINGLE STAGE WITHOUT BOOST

ENGINE STARTING STANDBY

END CELL VOLTAGE

0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0

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 Operating Environment &
Battery Life

42
 Battery Characteristics (Temperature)
This is one of the main factors that affects the electrochemical activity.
Battery performance is stable in temperature range 15 oC to 25oC.

CHARGING EFFICIENCY - Decreases with temperature rise

INTERNAL RESISTANCE - Decreases with temperature rise
DISCHARGE PERFORMANCE - Improves with temperature rise,
Unchanged above 25oC
SELF DISCHARGE - Increases with temperature rise
CHARGING VOLTAGE - Decreases with temperature rise. Voltage
drops 3mV per oC temperature rise for each
cell.
WATER LOSSES - Increases with temperature rise
LIFE - Decreases with temperature rise, but
affected much less compared to lead
acid batteries

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 Battery Characteristics (Temperature)
AVAILABLE CAPACITY VS TEMPERATURE
105
AVAILABLE CAPACITY (% )

Degradation due to charging efficiency

100

95

90 Degradation due to discharge performance

85

80
-25 -15 -5 5 15 25 35 45

TEMPERATURE oC

• Nicad batteries can operate continuously between –20 oC to +55oC

• To avoid ageing, it is preferred to use battery below 45 oC.
• Low temperature performance of Nicad far superior to Lead acid.
Operations at –30oC possible with special electrolyte.

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 Battery Characteristics (Temperature)

45
 Battery Characteristics
Resistance to abuse & harsh environment

Nicad batteries are resistant to different kinds of abuse –

Electrical, Mechanical & Thermal. These are rugged enough to withstand harsh
operating conditions.
Over-charging :
• Nicad cells are capable of withstanding any extent of overcharge.
• Excessive overcharge can dry up cell. Overcharging with high current produces
vigorous gassing causing electrolyte splash & overheating of cell.
• Prolonged overcharging at high temperature (>40 oC) affects battery electrodes &
oxidizes felt separator(used in sintered & FNC).
• Frequent overcharging at high temperature to be avoided for long life of battery.
Over discharging :
• Over-discharging I.e. cell voltage drops below zero volt does not affects
performance of Vented Nickel Cadmium cell .
However there is a production of oxygen and hydrogen gases and water loss.

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 Battery Characteristics
Resistance to abuse & harsh environment

Ripple current :
• Nicad cells are resistant to ripple currents. A ripple current limited up to 10% of
C5 (0.1 C5A) is acceptable. Ripple current will induce additional heat generation
in the plate group.
• The sintered & FNC cell are more sensitive to this temperature effect than the
pocket cell, due to the differences in internal resistance which induces lower
thermal management.
Short-circuit :
• All the components of Nicad battery including electrodes are designed to
withstand short circuit (up to 23xC5 Amps current for KH) . Battery after complete
short circuit (upto 0 volt) can be recharged to deliver full capacity.
Storage :
• Filled Nicad cells can be stored months together in any state of charge – fully
discharged, fully or partially charged. Fully discharged cells can be stored in dry
condition for any length of time..

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 Battery Characteristics
Resistance to abuse & harsh environment

Mechanical abuse :
• Cell containers are made of polypropylene or stainless steel and all other
components are made of steel. Nicad batteries have the best capability to
withstand shocks and vibrations.

Chemical abuse :
• All metallic components are Nickel plated and PP/ SS cell cases are resistant to
severe environment of Chemical / Petrochemical industry and off-shore. Small
quantity of gas is always produced in cell on float charging, maintaining internal
pressure little more than ambient. This prevents air from entering cell, hence
electrolyte is not contaminated.

Thermal resistance :
• There is no physical damage to battery for peak temperature up to 100 oC.
Batteries can operate continuously at 55 oC. Cells are designed to resist ambient
temperatures from - 50°C to + 70°C

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 Battery Life

49
 Battery Characteristics (Life)

Ageing of Ni-cad batteries is slow and gradual, without sudden failure

The lifetime of a nickel-cadmium cell in stationary applications is in excess of 20
years.
Battery is considered to be healthy till it meets the designed load requirements.
Normally batteries are sized with 15 to 25% excess capacity as ageing allowance.
An aged Ni-cad battery with 70% capacity can still provide reliable backup.
Life of Ni-cad battery depends upon :
• Number of charge discharge cycles and depth of discharge.
More the depth of discharge lesser is the cycle life.
• Operating temperature.
Life reduces at high temperature, but the effect is much less than in case of Lead
acid batteries.
• Over-charging & deep discharging.
Though Nicad batteries can withstand over-charging & deep discharging, its life is
affected by prolonged overcharge & repeated deep discharges.
• Composition of ingredients in Active mass

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 Battery Characteristics (Life)

CYCLE LIFE VERSUS DEPTH OF DISCHARGE (DOD)

10000

8000
CYCLES

6000

4000

2000

0
10 20 30 40 50 60 70 80 90
DOD (%)

Cycle life is not a concern for standby applications

51
 Battery Characteristics (Life)

10°C temperature increase shortens life of Nicad battery by 20%. Where as capacity
of Lead acid battery reduces to 50% for 10°C temperature increase.

52
 Battery Characteristics (Memory Effect)
This phenomena is observed in sintered plate satellite batteries. After repeated
shallow cycles (25% DOD) when battery is deep discharged a pronounced voltage
step is noticed. Memory effect is erased once cell is discharged below 1.0V &
recharged
A large part of active masses remains unused during shallow cycling. The inactive
part of negative active mass grows into larger crystals. Large crystals has less
surface area and are difficult to discharge.
Memory effect not observed in industrial Nicad batteries. Expander such as Iron
oxide present in negative active mass helps to maintain small crystal size.

Normal discharge after a full discharge /charge cycle

VOLTAGE DROP = MEMORY EFFECT M

Discharge of memorized cell

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 Battery Characteristics (Floating Effect)
When Nicad cell is on float over a period of time, there is a decrease in the voltage
level of the discharge curve of about 40mV/cell, though capacity to 1.0V is slightly
increased.
This effect begins after approximately one week and reaches its maximum level
after approximately three months. This is common in all types of Nicad
technologies.
This effect can be eliminated by a full discharge/charge cycle, but not eliminated by
a boost charge.
Formation of -form of NiOOH on long floating causes voltage depression.

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 Battery Characteristics
Carbonation of Electrolyte
Accumulation of carbonate in the electrolyte occurs due to absorption of atmospheric
carbon dioxide, from low quality topping-up water or, anodic oxidation of the graphite
in the positive electrodes.

This latter phenomenon is particularly important at high operating temperatures, and

cycling service at the same time (Railways applications)
Mainly, at low temperature a high level of carbonate can reduce the performance
and capacity of the cell due to increased cell internal resistance.

It is generally recommended that the level of carbonate should not exceed 80g/l. For
stand by applications carbonate does not exceed this limit during life time of battery.

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 THANK YOU

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