- (1) Project Group Member:

Asif Naveed Wajid Iqbal Islam Subhan

Adviser:
Prof. Abid Karim Researched by: Islam Subhan

Project Researched Paper On

BATTERY REGENERATION
I have found two methods for battery Regeneration/Rejuvenation/Restoring/Refurbishing/Reconditioning/Desulfation. 1st : Magnesium Sulfate (Chemical Solution). 2nd : EDTA Acid (Chemical Solution).

BATTERY ENERGIZER
(Magnesium Sulfate)
Magnesium Sulphate is a chemical compound containing magnesium, sulfur and oxygen, with the formula MgSO4. It is often encountered as the heptahydrate epsomite (MgSO47H2O), commonly called Epsom salt, from the town of Epsom in Surrey, England.

Formula Molecular Weight Magnesium content Sulphuric content 1st Method and Process:

MgSO4.7H2O = 246.48 = 9.86% = 13.0%

Following is a reconditioning battery guide to help you get started. 1. Prepare the following items: - battery hydrometer - battery load tester - battery post cleaner - volt meter - Epsom salts - plastic funnel - screwdriver - safety gear (gloves and glasses). 2. Clean the battery posts on both sides of the battery by using a battery post cleaner. 3. Check the battery's voltage with the volt meter. If the reading is less than 12 volts, you'll have to check the individual battery cells. To do this, pry the battery caps open with a screwdriver and then hook up some lead wires onto your volt meter. Make sure that you do not hook the volt meter's leads directly to the battery cells as it can get ruined by the acid content. Place the meter's positive lead on to the battery's positive post and the meter's negative lead on to the first cell and then take a reading. Next, place the positive lead of the meter on the first cell and its negative lead on the second cell and take another reading. Continue the pattern until you get a reading on all battery cells. If ever you get a reading of less than two volts, then this means that it might be a bad cell that needs replacing. 4. After checking the voltage, you'll need to run a battery load test. To do that, hook the load tester's leads to the battery and then take a reading (Be sure to hook the positive lead before the negative lead). Your load tester should register a minimum of 12 volts. Now, turn the switch of your load tester on and hold it for around ten seconds. After that, let go of the load tester's switch. When you do so, the load tester should at least register at least 9 volts. Remove the leads, this time with the negative lead coming off first.
Researched, Created and Composed by: ISLAM SUBHAN BATTERY REGENERATION Advised by: Dr. Abid Karim

- (2) 5. Next, you'll need to perform a hydrometer test. Attach the hydrometer's end to the first battery cell. To begin, squeeze the top part of the hydrometer and then let go. You should notice that the level of the fluid should stay within the green area or just below it and the item in the glass tube should float. If the fluid passes through the green area, then the battery will need recharging. On the other hand, if it does not reach the green area, the battery is still in good condition. Repeat the process on each of the battery's cells. 6. Finally, you are ready to add the Epsom salts to the battery. Take the plastic funnel and place it over one of the battery cells. Pour 2 to 4 tablespoon of Epsom salts into each of the cells and then charge the battery for about 24 hours.

2nd Method and Process:

To recondition your lead acid battery you will need Epsom Salt, and a quart of distilled water. Warm up the water to about 150 degrees (very hot but not boiling). The temperature doesn't need to be exact and will still work even if the water is at room temperature. Mix 5 to 10 heaping table spoons full of Epsom Salt into the water and stir until most is dissolved. Most batteries will be low on fluid so adding this solution will not over flow the battery. If not, remove enough electrolytes in the battery to allow this mixture to be added. Just below the plates is optimal. (Approx 4 oz per cell). If they are totally dry, you may not be able to save the battery because the lead plates are most likely ruined. Then simply pour this warm solution into your battery where you would normally put water to maintain the acid levels. Do not attempt to put Epsom Salt directly into your battery because it will not dissolve into the battery acid, only water will dissolve Epsom Salt. After adding the solution it is recommended to put the caps back on. Place on charger for minimum of 14 hours. It will improve the performance after this first charge; however it takes about a week to fully remove sulfates and optimize the battery capacity. Each time you use and recharge the battery will get closer to original condition. Driving around will help agitate and remove sulfates. If you take a battery Hydrometer reading before and after this procedure you should see a noticeable improvement. This is the best way to measure results.

3rd Method and Process:

Using Epsom salt, follow these easy steps: Heat up the water to about 66C (150F), mix 10 to 15 heaping tablespoons of Epsom salt into the water and stir until dissolved. The consistency of the brew should vary according to the extent of the sulfation. Avoid using too much salt because a heavy concentration will increase corrosion of the lead plates and internal connectors. Then simply pour this warm solution into the individual cells of your dead battery just as you would normally put water to maintain the acid levels. Be careful not to overfill. Do not place un-dissolved Epsom salt directly into the battery because the substance does not dissolve well. In place of Epsom salt, try adding a pinch of caustic soda. Then Charge or equalize the battery over night after service. If battery does not appear to have good capacity after the overnight charge, dont give up. Sometimes it takes a week to 10 days for the Epsom Salt solution to work on the battery plates. Agitation is important. It is difficult to get the Epsom Salt solution to thoroughly mix with the acid in your battery because of the battery plates and baffles.

Note:

ALWAYS WEAR SAFETY GOGGLES AND GLOVES WHEN WORKING WITH ACIDS!

Researched, Created and Composed by: ISLAM SUBHAN

BATTERY REGENERATION Advised by: Dr. Abid Karim

- (3) -

BATTERY EXTENDER
( Ethylene diamine tetra acetic acid )

Chemical Formula: C

10H12N2O8

4Na

Chemical Name: Ethylenediaminetetraacetic Acid (EDTA) Molecular Weight: 380 (292 as acid) Purpose: Scale prevention. EDTA sequesters di- and tri-valent metal ions such as calcium, magnesium, iron, manganese, copper, and zinc in aqueous solutions. Applications: Boiler scale inhibitor. pH Effects: Not affected by extremes in pH. Solubility: Commercially, EDTA sodium salt comes as a 38% solution. Reactivity: Is a sequestering agent that reacts with di- and tri-valent metal ions. Incompatibilities: Will accelerate corrosion in the presence of oxygen. Should only be fed to mechanically and chemically de-oxygenated boiler feed water. Other Information: It is recommended to feed EDTA downstream of the feedwater pump to protect the impeller in times of oxygen upsets unless the impeller is made of stainless steel. Functionality: EDTA sequesters di- and tri-valent metal ions such as Calcium, magnesium, iron, manganese, copper, and zinc in aqueous solutions. The stoichiemetyr is 1:1 on a molar basis or 3.8 ppm EDTA per 1 ppm Hardness ion expressed as CaCO3.

1st Method and Process:

Dissolve the EDTA in as small amount of distilled water as possible. Gently heating the solution will assist the process & also reduce the quantity of water required. Ensure the electrolyte level will not exceed the cells capacity once the additional solution is added; if necessary draw a small quantity of electrolyte off. Divide the EDTA solution equally between the 6 battery cells. Apply a high level (slow charge 5A) of charge to the battery for 24-48 hours & then reduce to a trickle charge if your battery charger has this capability. Monitor the battery for an increase in the underlying battery voltage. The initial voltage reading on disconnecting the charger is the float or surface charge & can be a bit misleading. Ideally a load should be briefly applied to the battery to reduce this & give you a more accurate reading.

Researched, Created and Composed by: ISLAM SUBHAN

BATTERY REGENERATION Advised by: Dr. Abid Karim

- (4) 2 Method and Process:

nd

Some people just dump it into the battery (it's in powder form) but that gives the sulfates a chance to precipitate out of solution and settle in the bottom of the battery. I'd prefer to get those nasty sulfates out of the battery totally. I mix a solution of 1 tablespoon to one quart of water. Empty the acid from the battery; Try to keep the acid clean, as you'll probably want to reuse it. Rinsing the battery out with distilled water can't hurt either. Please note that fluid/acid/water will "stick" between the battery plates, especially when that space is filled up with sulfates, and it can be difficult to get all of it out! A bit of shaking is sometimes warranted, or maybe several rinses with distilled water. I refill the battery with the EDTA solution and leave it overnight. This is a fairly weak solution, and you may wish to double the strength for this purpose. Also, keep the solution away from light so it won't break down. The next day the solution should look milky when you pour it out of the battery. Anyway, repeat the process until the battery is noticeably cleaner (the white sulfate on the plates should be disappearing). Sometimes one cell will be much more sulfated than others, and you may wish to treat that cell only. Heat will speed up the process, although I wouldn't get too carried away trying to heat up your batteries! When the process is done, put the old acid back in, unless you happen to have new acid kicking around. If you do have new acid, then make sure it's properly mixed with water. Another trick I've heard of for reviving batteries is to drain/save the acid, fill them with distilled water, and charge them (overnight, at low current). Do this 2-3 times and it might take some sulfates off of the plates. I'll check into this as it might not be very effective. I think the most reasonable approach for heavily sulfated batteries will be to treat them chemically, then leave them pulsing with the electronic device for a while.

3rd Method and Process:

The processes used to prevent sulfation and rejuvenate lead acid batteries with EDTA is simple enough and may be worth the money. After putting on all needed personal protective equipment, carefully remove all old electrolyte from battery (ie.Rinse all cells with clean, preferably deionizedor demineralized water Add 2 tablespoons of EDTA that has been dissolved in hot deionized or distilled water, to each cell chamber of the battery. (Again- have personal protective equipment on!) There will be a reaction- bubbling and some fuming. Let EDTA work for 4 to 6 hours or until bubbling stops. Repeat process of emptying chambers in battery, dissolving EDTA in hot deionized or deminerlaized water and letting it work several times until the plates are clean as evidenced by water being clean. Replace Sulfuric Acid in to batteries and recharge.

Note:
ALWAYS WEAR SAFETY GOGGLES AND GLOVES WHEN WORKING WITH ACIDS!

Researched, Created and Composed by: ISLAM SUBHAN

BATTERY REGENERATION Advised by: Dr. Abid Karim