
How to restore and prolong lead-acid batteries
The sealed lead-acid battery is designed with a low over-voltage potential to prohibit the battery from reaching its gas-generating state during charge. This prevents water depletion of the sealed system. Consequently, these batteries will never get fully charged and some sulfation will develop over time.
Finding the ideal charge voltage threshold is critical and any level is a compromise. A voltage limit above 2.40 volts per cell produces good battery performance but shortens the service life due to grid corrosion on the positive plate. The corrosion is permanent. A voltage below the 2.40V/cell threshold strains the battery less but the capacity is low and sulfation sets in over time on the negative plate.
Driven by diverse applications, two sealed lead-acid types have emerged. They are the sealed lead acid (SLA), and the valve regulated lead acid (VRLA). Technically, both batteries are the same. Engineers may argue that the word 'sealed lead acid' is a misnomer because no lead acid battery can be totally sealed.
The SLA has a typical capacity range of 0.2Ah to 30Ah and powers personal UPS units, local emergency lighting and wheelchairs. The VRLA battery is used for large stationary applications for power backup. We are looking at methods to restore and prolong these two battery systems separately.
Valve regulated lead-acid (VRLA)
The charge voltage setting on VRLA battery is generally lower than SLA. Heat is a killer of VRLA. Many stationary batteries are kept in shelters with no air conditioning. Every 8°C (15°F) rise in temperature cuts the battery life in half. A VRLA battery, which would last for 10 years at 25°C (77°F), will only be good for 5 years if operated at 33°C (95°F). Once damaged by heat, no remedy exists to improve capacity.
The cell voltages of a VRLA battery must be harmonized as close as possible. Applying an equalizing charge every 6 months brings all cells to similar voltage levels. This is done by increasing the cell voltage to 2.50V/cell for about 2 hours. During the service, the battery must be kept cool and careful observation is needed. Limit cell venting. Most VRLA vent at 0.3 Bar (5 psi). Not only does escaping hydrogen deplete the electrolyte, it is highly flammable.
Water permeation, or loss of electrolyte, is a concern with sealed lead acid batteries. Adding water may help to restore capacity but a long-term fix is uncertain. The battery becomes unreliable and requires high maintenance.


