Production

Amara Raja Batteries private limited was incorporated under the Companies Act 1956, in 13th 1985 & converted into a public limited company on 6th Sep 1990. The company is situated in 100 acres. ARBL is the first Indian who manufacturers VRLA (Valve Regulated Lead Acid) batteries. ARBL is the only public limited company among the group companies. At first ARBL was in collaboration with GNB Industries (USA) & later onwards, Now ARBL is having collaboration with Johnson Controls Inc., (JCI-USA) which is the largest manufacturer of VRLA batteries in North America. The present turnover of the company is $350 & mainly aimed at producing the highly qualified VRLA batteries.

ARBL as whole has 4 divisions; 1. 2. 3. 4. Industrial Battery Division (ABD) Automotive Battery Division (IBD) Small Battery Division (SBD) Injection Mold Division (IMD-Plastics)

MANUFACTURING PROCESS

OXIDE PLANT: OXIDE PREPARATION: Lead oxide preparation involves either of two methods of

manufacturing: a) Ball-Mill Process b) Barton- Pot Process With either methods, the oxide usually contains about one part un reacted fine lead particles i.e free lead and three-part lead monoxide. In both process, 99.97% lead is used. 1.1 BALL MILL PROCESS: i) ii) Lead ingot is tumbled in a melting point, which is rotated with its central axis in the horizontal plane. The heat generated by the friction between the lead cylinders is sufficient to start oxide formation in the presence of stream of humid air, which is passed through the drum. iii) This reaction generates more heat and the particles of lead that are rubbed of by the abrasion are converted to leady oxide of the required chemical composition.

iv)

The oxide removed by the entertainment in the air stream or by discharge through small holes located in the periphery of the drum.

1.2 BARTON POT PROCESS: 1.2.1 MELTON POT: Function: i) ii) iii) melting the lead ingot i.e 99.97% lead A rectangular pot with the immersion haters provided at two opposite side of the pot. Thermostats provided at the top, middle and bottom to maintain the constant temperature in order to keep the lead in molten state. iv) Hood is provided to prevent the spillage of lead during 1.2.2 REACTOR POT: The molten lead from the melting point is pumped through rotary pump through a duct into the reactor pot. Function: i) ii) iii) It converts molten lead into lead oxide by oxidation process. (exothermic process). The agitator provided disperses molten lead and keeps them better with oxygen. Distilled water is added to reduce the ultra- fine powder of lead oxide and helpful to reduce the temperature of the reaction. the high temperature. The vapours are sucked, filtered and sent to the atmosphere.

iv) Bottom heaters are provided to increase the temperature during the initial start-up period. Reaction : i) air react During oxidation reaction, the oxygen from the with the droplets of molten lead to produce an oxide coating ii) iii) Usually 15-30% free lead exists at the core of each fine oxide spherical shaped particle. The lead oxide formed is sucked by vacuum created by the blower, which is present outside the bag house i.e., the lead oxide is separated by cyclone into the heavier and lighter particles (size) and is filtered in bag house. 1.1.3 REST PART: The oxide particle from the reaction pot, are drawn out from it through a duct connected to a classifier. For segregation particles of desired size then passes through the classifier into a cyclone. In the cyclone, oxide particles drop down through the contact walls into a screw conveyor. Very fine particles of lead oxide remaining in the air stream are drawn out of the cyclone and passed into a dust collector where special filters separate the oxide from the air. The fine oxide is removed from the filter bags by high pressure air pulses and fed to the screw conveyor. The finished oxide is then stored in silos from where required quantities are transferred for production.

around each droplet of lead.

GRID CASTING: The grids are casted by fully automatic casting machine using different moulds in order to get the desired design of grids. Pure lead does not possess sufficient tensile and creep strength and thus is easily deformed at room temperature. Because grid imparts plate strength during manufacturing and life, it must be durable. This is accomplished by alloying lead with other elements the primary alloying ingredients are antimony, calcium, tin and cadmium. The other elements are arsenic, selenium and silver etc., being used in lesser amount. Grids in battery perform two vital functions. It acts as the mechanical support frame work of the plates (active material). It provides uniform efficient current flow to and from the plate (active material) during formation and use. In automotive battery division raw materials used for positive grids are high tin, silver, 1.47antimony and for negative grids lead calcium alluminium (LCA) In industrial battery division raw materials used for positive grids are MFX (lead cadmium antimony) and for negative grids lead calcium aluminum(LCA). PASTE MIXING:

The lead oxide powder, distilled water and dilute sulfuric acid are mixed thoroughly in a paste mixture to form a paste. The paste is used for making active materials for both positive and negative plates. The purpose of adding sulfuric acid is mainly to provide the basic sulfates and causes the required cementation. And the addition of water forms pores in the basic plate. The positive and negative plates differ only in additives to the base mixture. The binder added to the positive plates is basically to bind the material with bbasic frame work and enhances the mechanical strength. Organic expanders like barium sulfate (baso4), carbon black and dynel fibers are added to the negative plates. Carbon is used to improve the plate conductivity. The water added during the mixing operation functions as a lubricant and bulking agent to produce a paste for proper consistency. The mixture has a setup for cooling air in order to reduce the heat during the mixing operation PASTING: The pasting is done on an automatic pasting machine ORIFICE PASTER.

1) The paste is dumped into a cone then transferred to hopper. 2) Grids are automatically fed into the machine by a mechanical feeder. 3) The quantity of paste dispensed through the hopper is automatically controlled and a pasted plate comes out through conveyor belt at the other end of the pasting machine. 4) The plates are staked in sequence for curing and drying process. CURING AND DRYING: CURING: Curing is the process by which satisfactory levels of cohesion & adhesion are imparted to the active material prior to formation. The nature and degree of interlocking between the crystals of the paste determine curing. Adhesion is dependent upon the strength of the bond, which is formed between the paste and the grid. These to essential properties are the best accomplished by conducting the curing procedure in the following sequence: Steaming period: To equalize the moisture content between all the plates and to encourage the development of basic lead sulfates.

Lower humidity treatment to affect the oxidation of free lead: Drying process to bring down the water content (moisture) to the low level for the active material to have good stability.

During curing process physical, chemical and morphological changes take place within the active material. These changes are brought by at least four reactions. i) ii) iii) iv) Progressive growth of basic lead sulfate crystals. Development of basic lead carbonates. Conversion of free-lead particles to lead oxide with the liberation of heat. Corrosion attack of metal/alloy grid. These four reactions cause the active material to harden, strengthen and bond well to the grid. The development and the growth of the basic lead sulfates provide the essential particle-to-particle cohesion that enables the active material to withstand the regular contraction forces which are encountered the course of the battery discharge- charge service. In simple terms, the effectiveness of the curing process can be evaluated both by the degree of free-lead oxidation and by the amount of moisture remains in the material after the process has completed with the specified condition. DRYING:

After curing, the active material is still a paste. It is considered that this process enhances the mechanical strength of the active material and allows plates to be stored without risk of degradation. ASSEMBLY: After curing and drying, plates are sent to the assembly where positive and negative plates are arranged alternatively as per the end use of the battery. The plate is enfolded with the AGM (absorbent glass mat) separator for VRLA and fiber glass for automotive batteries. The following process take place one after other Envelope stacker: prepares a stack of plates (set of positive and negative) Caston trap: prepares groups (group of plates) with straps and end terminals HVPT (high voltage polarity test): conducts high voltage polarity tests ICW (inter cell welding): welds one cell with other internally. Heat sealing: seals cover with container Post burning: prepares positive and negative post. Leak testing: conducts a battery leak test.

Based on design, plates are alternately arranged (with one plate wrapped with separator) to form a group of plates which are known as stakes. The lugs of grouped plates (along with separator) will be fused together with an alloy which is known as straps and finally two terminals are casted to represent the terminals of the battery. Then those groups are inserted into the polypropylene jar and tested for any damages in HVPT machine then all the cells are welded internally and will be sealed with cover and after post burning finally the battery is leak tested. Now assembled battery is known as DUF (dry unformed) battery. FILLING AND FORMATION: DUF batteries are filled with chilled dilute sulfuric acid in acid filling machine, which is basically semiautomatic vacuum filler. The dilute sulfuric acid should be fed at low temperature to control the temperature during filling and formation. Then it is sent to the formation section where cured plate material is electrochemically converted into electrode active material i.e. spongy lead as negative and lead dioxide as positive, utilizing direct current supplied material present. by power sources. Formation time and charging pattern depends on the plate count and the amount of active

The formation process converts the unformed masses to charged state. The pasted and cured mass in the positive plate contains lead monoxide, lead sulfate and lead. Similarly negative mass also contains lead monoxide, lead sulfate and lead along with additives. The conversion these masses involves the formation of lead dioxide with tetravalent lead on the positive electrodes and spongy lead on the negative electrodes in a process carried out electrochemically in a solution of sulfuric acid. Positive plate (anodic process or oxidation) PbSO4 + 2H2O PbO + H2O -----> PbO2 + 2H + + 2e- +H2SO4 -----> PbO2 + 2H + + 2e-

Negative plate ( cathodic process or reduction) PbO2 + 2H+ + 2ePbO + 2H+ + 2e------> ------> Pb + H2SO4 Pb + H2O

FINISHING: After forming, battery is closed with vent plug and washed to remove any acid present on the battery cover/container.

Then it is checked for their prescribed capacity. The batteries, in which satisfy the specification is packed and labeled. This finished product is sent to the market through shipment by Lorries, trucks etc. Acid top up: in this section acid is filled or leveled in the batteries. Battery washing plant: the battery is washed with clean water. Vent cap fixing: permanent caps are fixed. HRD test: battery tested for high rate discharge.

Post polishing: finishes the post Serial number punching: serial number for the battery is punched then caps are fixed after labeling. Web sealing: battery is sealed with a polyethylene cover. Stretch wrapping: batteries are packed.