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Calculating Hydrogen
Concentration
Determining Ventilation
Requirement
Determining Fan
Requirement
The information below is provided for reference only. State and local codes may apply that supersede these
guidelines. The following is for general understanding only, and GB Industrial Battery takes no responsibility for
these guidelines.
A typical lead acid motive power battery will develop approximately .01474 cubic feet of hydrogen per cell at
standard temperature and pressure.
H = (C x O x G x A) R
100
(H) = Volume of hydrogen produced during recharge.
(C) = Number of cells in battery.
(O) = Percentage of overcharge assumed during a recharge, use 20%.
(G) = Volume of hydrogen produced by one ampere hour of charge. Use .01474 to get cubic feet.
(A) = 6-hour rated capacity of the battery in ampere hours.
(R) = Assume gas is released during the last (4) hours of an 8-hour charge.
Example: Number cells per battery = 24
Ampere size of battery = 450 A.H.
(H) = (24 x 20 x .01474 x 450) 4
100
H = 7.9596 cubic feet per battery per hour
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Hydrogen Concentration Worksheet
and is used in the electrolysis. As the battery reaches its full state of charge, the
acceptance of current becomes less and the liberation of hydrogen is more.
Four percent (4%) concentration of hydrogen is dangerous and has a potential for an
explosion. Generally, the maximum allowable concentration of hydrogen is 1.50% of
the room's cubic footage. To keep the hydrogen concentration below 4%, adequate
ventilation must be provided.
Rate of Hydrogen Release
1 Ampere x 1 Hour x 1 Cell = 0.016 cubic feet / Ampere Hour / Cell
Battery Hydrogen Calculation
Ampere Hour x Finish Rate (percent) x Number of Cells x 0.016 Cubic Feet / Ampere
Hour / Cell
Example:
Quantity = 10 Batteries
Type = 18-85-21
Ampere Hour = Ampere Hour per Positive x Number of Positive Plates
Ampere Hour = 85 Ampere Hour Plate x 10 Positive Plates
Ampere Hour = 850 Ampere Hour
Battery Hydrogen Calculation
850 AH x 0.05 x 18 Cells x 0.016 Cubic Feet / Ampere Hour / Cell =
12.24 Cubic Feet / Hour / Battery x 10 Batteries = 122.40 Cubic Feet / Hour
Room Calculation
40' Long x 30' Wide x 15' High = 18,000 Cubic Feet
18,000 Cubic Feet x 0.015 (Maximum Allowable Concentration) = 270 Cubic Feet
(Maximum)
Rate of Concentration Calculation
270 Cubic Feet (Maximum Allowable) 122.40 Cubic Feet / Hour = 2.2 Hours or
132 Minutes
Rate of Air Volume Removal
18,000 Cubic Feet 132 Minutes = 136.40 Cubic Feet / Minute
BATTERY TUTORIAL
While there are many battery chemistries today, and new types becoming commercially
viable over time, we deal with the lead acid types, flooded, AGM, and true Gel, as they
are widely used in the applications we specialize in. Lead acid battery technology has
been used commercially for over a century. Some archeological finds of the appropriate
materials in a man made configuration suggest the principle has been known and used
much longer than that. Their construction is of lead alloy plates, and an electrolyte of
sulphuric acid and water. A battery is made up of a number of cells, and the lead acid
chemistry dictates a fully charged voltage of about 2.12 volts per cell. Thus, a nominal 6
volt battery has three cells with a full charge voltage of 6.3 to 6.4 volts, and a 12 volt
battery has six cells, and a full charge voltage of 12.7 volts. High quality, high
performance lead acid batteries may may exhibit higher cell voltage.
The cell has two plate types, one of lead and one of lead dioxide, both in contact with
the sulfuric acid electrolyte as either a liquid, absorbed in a mat, or a gel. The lead
dioxide (PbO2) plate reacts with the sulfuric acid (H2SO4) electrolyte resulting in
hydrogen ions and oxygen ions (which make water) and lead sulfate (PbSO 4) on the
plate. The lead plate reacts with the electrolyte (sulfuric acid) and leaves lead sulfate
(PbSO4), and a free electron. Discharge of the battery (allowing electrons to leave the
battery) results in the build up of lead sulfate on the plates and water dilution of the
acid. More on sulfation and its problems later. The specific gravity of the electrolyte as
measured with a hydrometer in flooded batteries, indicates its relative charge (strength),
or level of dilution (discharge). The reversibility of this reaction gives us the usefulness
of a lead acid battery. The sealed versions contain the water, hydrogen, etc. under
normal use, for recombination, and eliminate the maintenance of checking water levels,
and corrosion around the terminals.
Charging the battery is reversing the process above, and involves subjecting the battery
to voltages higher than its existing voltage. The higher the voltage, the faster the charge
rate, subject to some limitations. There is a gassing point to consider, and true gel
batteries have a lower peak charge voltage, because bubbles can occur in the gel which
don't dissipate, and result in battery damage. More on this in the charging tutorial.
The electrolyte may be absorbed into a mat type material so there is no free electrolyte
(AGM battery), or may be in a gel format which also stabilizes it (true Gel battery).
Current lead-acid batteries are basically distinguished as deep cycle/storage (rated in
amp hours), or automotive SLI type (Starting/Lighting/Ignition), rated in cranking
amps. There are also combination types, rated for both duties, but these usually have a
lower cranking amp rating than a starting battery of the same group size.
SLI Batteries
SLI batteries are designed to release a high burst of amps for a short time (a starting
sequence), and then be relatively quickly recharged from the equipment's charging
system (alternator). Typically, a starting sequence discharges less than 3% of the battery
capacity. SLI batteries are not designed for repeated deep discharge, and their life is
considerably reduced when subjected to this. There are wet (flooded) and totally sealed,
maintenance free batteries (AGM - absorbed glass mat) in this class. These generally
have a high plate count, and the plates are relatively thin. They are rated in CA,
cranking amps (at 32 degrees F), and CCA, cold cranking amps (at 0 degrees F).
Frequently the term "Gel" is used to refer to any truly sealed, maintenance free battery,
and this practice causes confusion to battery consumers, as the AGM and true Gel have
some different characteristics, particularly in the charging requirements of the true Gel.
Both types are maintenance free, have no liquid to spill and gassing is minimal. Other
names for the sealed types are starved electrolyte, maintenance-free, dry cell, and spill
proof. Most of these are Department of Transportation (DOT) approved for air
transport, and classified as non-hazardous.
The Gel is the least affected by temperature extremes, storage at low state of charge and
has a lower internal discharge rate, but has peak charge voltage requirements that are
measurably lower than a flooded or AGM battery. An AGM battery will handle
overcharging slightly better than the Gel Cell. Included in the AGM category are the
Optima and the Odyssey, as well as several other high performance sealed
batteries. The smaller batteries you find in house alarm systems, computer UPS
(uninterruptible power supply) boxes, etc., that say "sealed lead acid", "spill proof", or
"maintenance free", are almost always AGM type batteries. If it doesn't say "gel" on it, or
have a "G" in the part number, it's not a gel.
Battery capacity
Battery capacity is a measure of the energy the battery can store and deliver to a load. It
is determined by how much current a battery can deliver over an industry standard
period of time. The unit of measure is called "ampere hour" (ah). The battery industry
standard is a 20 hour rate, i.e. how many amperes of current the battery can deliver over
20 hours at 80 degrees F until the voltage drops to 10.5 volts for a 12 V battery and 21
volts for a 24 V battery. For example, a 100 ah battery will deliver 5 amps for 20 hours.
Occasionally a company or marketer will use a 10 hour rate or some other rate, so be
sure which rate you are given when comparing brands and group sizes.
Battery capacity is also expressed as Reserve Capacity (RC) in minutes. Reserve capacity
is the time in minutes a battery can deliver 25 amps at 80 degrees F until the voltage
drops to 10.5 volts for a 12 V battery and 21 volts for a 24 V battery. A relationship
between amp hours (ah) and reserve capacity (RC) can be approximated with this
formula: ah = RC times 0.6
BCI*Group
Battery Voltage, V
Battery AH
31
12
105
4D
12
200
8D
12
245
220
GC2
(Golf Cart)
Discharge Hours
Usable Capacity
20
100%
10
87%
83%
75%
70%
60%
50%
40%
This must be taken into consideration when sizing a battery for a particular application.
If it is a high current draw, battery capacity must be increased over the simple calculated
amp hour requirement.
Depth of Discharge
% of AH capacity
Cycle Life
Cycle Life
Cycle Life
Group 27/31
Group 8D
Group GC2
10
1000
1500
3800
50
320
480
1100
80
200
300
675
100
150
225
550
Internal discharge
Batteries are subject to an internal discharge, also called self-discharge. This rate is
determined by the battery type, and the metallurgy of the lead used in its construction.
Wet cells, with the cavities inside for electrolyte, use a lead-antimony alloy to increase
mechanical strength. The antimony also increases the internal discharge rate to between
8% and 40% per month. For this reason, wet cells should not be left unmaintained or
uncharged for long periods. The lead used in Gel and AGM battery construction does
not require high mechanical strength since it is stabilized by the gel or mat material.
Usually calcium is alloyed with the lead to reduce gassing and the internal discharge
rate, which is only 2% to 10% per month for the AGM and Gel batteries.
Any battery discharge, including internal discharge, produces sulphation on the battery
plates as part of the chemical cycle, and given enough time, this sulphation hardens,
causing diminished battery capacity at best, or total loss of function. Routine charging
after use, or use of a "floating" charger for long periods of storage (boat batteries, ATVs,
etc.) prevents this diminished capacity and maximizes battery life. A large portion
(approaching 50%) of lead acid batteries have diminished capacity or become unusable
due to sulphation, and never reach their rated lifespan. There are electronic devices
(chargers and stand alone devices) for dealing with sulphation, but the best practice is
avoiding the situation in the first place with proper battery management, including use
of quality 'smart' chargers.
season (jetski, snowmobile, ATV, etc.) are all things which contribute to good battery
life. Avoiding extreme temperatures, especially heat, when possible, and checking water
levels in flooded batteries are essential as well. There are some applications which are
more likely to reach the end of the cycle life of a battery, and have diminishing capacity
as a result. Wheelchairs and scooters used daily and heavily fall into this category.
I have added a page dealing with battery prices and the reasons they are rising and
probably will continue to do so for a while. This situation contributes to the reasons to
seek maximum battery life.
http://www.chargingchargers.com/tutorials/batteries.html
http://www.mkbattery.com/pdf/technical_manual.pdf