Acid Circulation Formation Charging System
Equipment process parameters and requirements
1. Scope of application: Acid circulation formation or charging for traction lead acid battery.
2. Applicable range of battery specification: 12V, all specifications.
3. Production efficiency: 288 pcs/unit, two units totally; Total acid adding time < 30min.
4. Deviation value during operation: 72 batteries are in series as one formation or charging circuit, and the deviation value is ≤2A.
5. Acid temperature during circulation: 30ºC ~ 55ºC.
6. Acid density in the circulation process: it can be adjusted in the density of 1.100g/cm3 ~ 1.300g/cm3 as required, and the density used for conversion (density 1.100 coefficient 0.00052, density 1.200 coefficient 0.00068, density 1.280 ~ 1.300 coefficient 0.00074 ~ 0.00075).
7. During the circulation, the surface of the battery is dry, no acid leakage, and the acid exchange time is 3h ~ 4h.
8. Quality: the electrolyte liquid position is consistent after formation or charging, and its density range is ≤±0.003 g/cm3 (25ºC).
Equipment Main Technical Parameter
1. Power supply: three-phase 380V+N wire (AC380V/50HZ), power 26kW.
2. External dimension: (L)14400mm (excluding control cabinet and charger) × (W)2500mm× (H)4500mm.
3. Equipment weight: 5000kg.
4. Equipment type and number of stations: automatic assembly, 24 stations (24 batteries as a group).
5. Each battery cell is equipped with a set of circulation pipeline, which is displayed with electrolyte flow in the circulation state, so that operator can clearly identify whether the pipelines are unblocked in the process.
6. Acid circulation velocity adjustment mode and range: frequency conversion speed regulation, speed regulation range: 20m m3/h ~ 40m m3/h.
7. Acid circulation working pressure: 0.2mpa ~ 0.4mpa.
8. Air source: pressure 0.4mpa ~ 0.6mpa, flow ≥1m3/min.
9. Water source (pure water) : pressure ≥ 0.03mpa, pressure difference (3m), flow ≥1m3/h.
10. Acid source (concentrated sulfuric acid) : pressure ≥ 0.03mpa pressure difference (3m), flow ≥0.5m3/h.
The 30kPa (3m) of the water source and acid source is the minimum height to supply pressure and high tank platform.
Equipment operation process, main technology and safety and environmental requirements
1. Operation Process
1)Manually insert circulation pipeline connector
2)Automatic acid mixing/ adjustment and cooling
3)Acid filling
4)Acid circulation and adjustment during process
5)Remove circulation pipeline connector manually
2. Running Process Main Technical Requirement
2.1 The system includes: circulation pipeline, independent circulation operating subsystem, negative pressure extraction temperature control system, acid fume primary treatment device and electrical control system.
2.2 Acid density in the battery can be adjusted free according to requirements.
2.3 The current bias in the charging and discharging acid circulation is small, and the consistency and uniformity of acid density, and temperature in the battery are ensured.
2.4 System structure and materials used.
2.4.1 Plastic structure:
All the materials used in the plastic structure of the system can meet the requirements of temperature, pressure and acid resistance of the stored or flowing liquid.
a) circulating acid tank: PP material, acid density adjustment and temperature control are all carried out in circulating acid tank, with reliable sealing and strength. There is collection structure in the acid tank, which is convenient for customers to empty and clean the acid tank. The tank body is equipped with transparent liquid level display tube. Circulating tank is equipped with liquid level and temperature sensor;
b) high density acid and low density acid storage containers: adopts enhanced PP material, and equipped with transparent liquid level display tube and liquid level sensor;
c) pipeline and maintenance valve: all liquid inlet and outlet of containers shall be equipped with maintenance valve (double ball valve), which shall be closed to prevent acid outflow during maintenance. Pipes and valves are made of high quality PVC and PP materials, with the features of low fluid resistance, good water hammer resistance, good chemical resistance, high environmental cracking resistance and high mechanical strength.
d) concentrated acid and pure water pipelines inside the unit connector;
e) battery circulation connector (injection nozzle) : imported transparent material, good comprehensive performance, high impact toughness and high mechanical strength, excellent oil and water resistance and chemical stability, electrical performance and cold resistance; High dimensional stability, low friction characteristics and certain wear resistance. meanwhile, through the clever design of the structure, the joint can be used easily and durable. The interface can be effectively sealed and easily rotated. It can be rotated 1000 times repeatedly without damage.
f) acid circulation pipeline interface sealant: when no external damage occurs, ensure no leakage of the system within 5 years.
2.4.2 rubber sealing structure: good elasticity, high temperature resistance, some parts have been treated with special anti-corrosion treatment.
2.4.3 flange fixed bolts and other stainless steel parts are all made of 316L material, with good acid resistance. Use butter to the bolts to prevent them from being stuck.
2.4.4 circulating power device: high-quality imported magnetic force driven centrifugal pump is selected, with reasonable piping and with the help of control software and electrical control system, the pump can run in the best working state for a long time.
2.4.5 temperature control device:
a) air cooling, fan frequency control, to meet the needs of cooling and heating in different seasons;
b) acid pump frequency conversion speed regulation, to ensure the normal circulation of acid and reduce the flow rate can increase the temperature difference between circulating acid and battery acid, reduce battery heat loss;
c) lead coil is arranged in the circulating tank and used for acid heating through steam;
d) reasonable layout of wind and acid pipes to reduce heat loss without starting cooling;
e) stop the circulation charging at the stage of small current at the initial stage, ensure the normal discharge of the air in the battery, and dilute it properly in the pipeline before discharging.
2.4.6 acid supply system is equipped with two bag filters.
2.4.7 acid fume treatment and exhaust device:
a) dispersed cooling device: surface dispersion mode, large specific surface area, low liquid holding capacity, high cost performance and low internal structural resistance;
b) blower: PP material, good anti-corrosion performance; The air volume meets the requirements of the whole system. The wind pressure can overcome the pressure loss of all exhaust ducts, ensure the air volume, and ensure the stable operation of the exhaust system with the wind speed sensor;
c) exhaust duct: good air tightness, appropriate pipe diameter, no weld joint at welding points, reducing pressure loss of exhaust duct.
2.4.8 all the hoses for circulation pipelines are made of EPDM.
2.4.9 the concentrated acid and pure water pipelines are equipped with pneumatic diaphragm valves
2.4.10 in the density adjustment stage, quantitative injection based on calculation is combined with density sensor measurement to ensure the accuracy of the adjusted density.
2.5 It adopts PLC programming control, touch-screen as the man-machine interface, realizing equipment work, parameter modification, storage (each product parameter can be saved, next time use direct access, reduce the adjustment), historical records; the operation status query and data export is through USB flash drive, and the touch screen will display equipment failure emergency alarm and alarm lights flashing, fault information prompt will ensure the system alarm information can be feedback and solved as soon as possible. The operation parameters of acid circulation system can be stored, transferred and printed, which is convenient for operation and maintenance personnel to inquire and exclude.
2.6 the whole process can be switched between automatic and manual mode.
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