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Avaliação do impacto da introdução de Red Lead nos processos de fabrico de pastas, sazonamento, tempo de soaking e carga de baterias chumbo-ácido AGM
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Este trabalho tem por objetivo estudar o impacto dos aditivos Red Lead (RL) e Read
Lead plus (RL+) na redução de tempo e energia necessários na etapa de formação das
baterias. Ademais, pretende-se avaliar o beneficio do aditivo RL+ no aumento de ciclos.
Estes aditivos foram fornecidos pela PENOX que, em colaboração com a EXIDE,
realizaram ensaios laboratoriais com 0, 10 e 15% de RL+ na pasta positiva tendo-se obtido
os seguintes resultados: uma conversão de sulfatos em cristais 4BS de 92.70% para as
placas com 10% e de 93,40% nas com 15% de RL+; uma redução no tamanho dos cristais
assim como uma estrutura cristalina mais homogénea com o aumento de RL+ na pasta;
um aumento da porosidade da pasta sazonada de 47% (0%RL+) para 52% (10 e 15% RL+);
uma redução do fator de formação de 4.0 (0%RL+) para 3.1 (10%RL+) e para 2.8 (15%RL+).
Realizou-se um ensaio industrial onde foram produzidas duas versões com 10 e 20% de
RL+. Reduziu-se o tempo de sazonamento de 49 para 29 horas. A versão com 10% atingiu
uma conversão de 56.8% em 4BS, a versão com 20% apresentou resultados melhores com
uma conversão de 74.4%. Reduziu-se o fator de formação atual de 6.8 para 5.2 (10%RL+)
e para 3.9 (20%RL+) que se traduz numa redução do tempo de formação em 18% e 28%,
respetivamente. As placas positivas formadas obtiveram 92.7% de 𝑃𝑏𝑂2 e 3.0% de 𝑃𝑏𝑆𝑂4
para a versão com 10% e, de 90.8% de 𝑃𝑏𝑂2 e 5.5% de 𝑃𝑏𝑆𝑂4 para a versão com 20% RL+.
Nos ensaios elétricos, C5, as baterias com 10% RL+ obtiveram uma média de 98.7% e, as
com 20%RL+, 95.4%. Através destes resultados e dos perfis de formação verifica-se que
ambas as versões necessitam de mais carga do que a aplicada durante a formação.
Com os dados teóricos da redução do tempo de formação estimou-se que a adição de
10% e 20% de RL/RL+ permite aumentar a capacidade anual em 244 e 522 mil baterias,
respetivamente. Realizou-se um estudo da viabilidade económica da implementação
do RL/RL+ tendo-se estudado dois cenários: com e sem aumento da capacidade fabril.
Perante todos os cenários e variações estudadas, conclui-se que a adição de 20% RL é a
versão que apresenta mais vantagens a nível financeiro. A implementação de RL permite
ainda reduzir as emissões de dióxido de carbono entre 258 e 1 238 mil toneladas.
The purpose of the work presented regards an analysis based on the impact of additive Red Lead (RL) and Read Lead plus (RL+) in the reduction of the necessary time and energy in the formation of batteries. Furthermore, it is intended to study the benefits of RL+ towards the increase of the cycle life of batteries. The previously mentioned additives were supplied by PENOX which, in collaboration with Exide, executed laboratory tests with 0, 10 e 15% of RL+ in the positive paste, obtaining the following results: a conversion of sulfates into 4BS crystals of 92.70% for plates with 10% and 93.40% in the 15% of RL+; a reduction in the size of the crystals as well as a more homogenous crystalline structure with increasing RL+ in the paste; an increase in the porosity of the curing paste from 47% (0% RL+) to 52% (10 and 15% RL+); a reduction in the formation factor from 4.0 (0%RL+) to 3.1 (10% RL+) and to 2.8 (15% RL+). Through industrial trials, versions with 10 and 20% were produced. The curing time was reduced from 49 to 29 hours. The version with 10% achieved an average conversion of 56.8% in 4BS and the version with 20% obtained a conversion of 74.4%. The formation factor was reduced from 6.8 to 5.2 (10% RL+) and to 3.9 (20% RL+) which allowed a reduction of the formation time by 18% and 28%, respectively. The positive plates formed obtained 92.7% of PbO2 and 3.0% of PbSO4 for the 10% version and 90.8% and 5.5% for the 20% version. In the electrical trials, C5, the 10% batteries reached an average of 98.7% and the 20% version, 95.4%. Analyzing the results and formation profiles it is concluded that both versions require more energy than the one supplied during formation. Based on the theoretical data, it was estimated that an addition of 10% and 20% of RL/RL+ allows an increase of the annual capacity by 244 and 522 thousand batteries, respectively. A study of the economic viability of the project was conducted according to two scenarios: with and without an increase in manufacturing capacity. Taking into consideration the given scenarios and variations studied, it was verified that the addition of 20% RL is the version presenting more financial advantages. Moreover, the RL implementation allows a reduction of 𝐶𝑂2 emissions from 258 to 1 238 thousand tons.
The purpose of the work presented regards an analysis based on the impact of additive Red Lead (RL) and Read Lead plus (RL+) in the reduction of the necessary time and energy in the formation of batteries. Furthermore, it is intended to study the benefits of RL+ towards the increase of the cycle life of batteries. The previously mentioned additives were supplied by PENOX which, in collaboration with Exide, executed laboratory tests with 0, 10 e 15% of RL+ in the positive paste, obtaining the following results: a conversion of sulfates into 4BS crystals of 92.70% for plates with 10% and 93.40% in the 15% of RL+; a reduction in the size of the crystals as well as a more homogenous crystalline structure with increasing RL+ in the paste; an increase in the porosity of the curing paste from 47% (0% RL+) to 52% (10 and 15% RL+); a reduction in the formation factor from 4.0 (0%RL+) to 3.1 (10% RL+) and to 2.8 (15% RL+). Through industrial trials, versions with 10 and 20% were produced. The curing time was reduced from 49 to 29 hours. The version with 10% achieved an average conversion of 56.8% in 4BS and the version with 20% obtained a conversion of 74.4%. The formation factor was reduced from 6.8 to 5.2 (10% RL+) and to 3.9 (20% RL+) which allowed a reduction of the formation time by 18% and 28%, respectively. The positive plates formed obtained 92.7% of PbO2 and 3.0% of PbSO4 for the 10% version and 90.8% and 5.5% for the 20% version. In the electrical trials, C5, the 10% batteries reached an average of 98.7% and the 20% version, 95.4%. Analyzing the results and formation profiles it is concluded that both versions require more energy than the one supplied during formation. Based on the theoretical data, it was estimated that an addition of 10% and 20% of RL/RL+ allows an increase of the annual capacity by 244 and 522 thousand batteries, respectively. A study of the economic viability of the project was conducted according to two scenarios: with and without an increase in manufacturing capacity. Taking into consideration the given scenarios and variations studied, it was verified that the addition of 20% RL is the version presenting more financial advantages. Moreover, the RL implementation allows a reduction of 𝐶𝑂2 emissions from 258 to 1 238 thousand tons.
Descrição
Palavras-chave
Red Lead Aditivos AGM Baterias Chumbo-Ácido