Gel batteries

	The GB200-12 from Guanzhen Science is suitable for UPS, solar power and electronic switching systems.

Product development emphasizes environment-friendly features, safety, longer battery life and higher reliability.

Environmental concerns and the need to boost competitiveness are prompting China lead-acid battery suppliers to focus on valve-regulated types. Models based on this technology now account for 50 percent of the country’s total output of batteries classified by structure and cap. Makers are confident the share will increase further as many companies emphasize this category.

Besides offering ecologically safe products, manufacturers are looking into alternative materials and developing new structure designs to improve cost management and bolster margins. A growing number are also implementing stricter waste management practices in compliance with local and international requirements.

Suppliers are riding on the robust global automotive industry to sustain the line amid declining sales resulting from the economic crisis. About 80 percent of China’s lead-acid batteries go to this segment. Two-thirds of such models target the replacement market, and the rest are sent to carmakers to be installed during vehicle assembly.

Demand from electric bikes, motorcycles and railway gas engines is likewise gaining momentum. E-bikes, in particular, are seen as a catalyst, especially for replacement batteries because existing models have a service life of only 12 to 14 months.

Companies concentrating on valveregulated models are setting their sights on the UPS, electric power and communications segments, where such variants can be used as a backup power supply.

Many are leveraging growing awareness about alternative energy sources such as wind and solar power to promote other battery types. Overall, they expect China’s lead-acid line to expand 20 percent annually in 2010-15, with production hitting $10.3 billion by 2015. The country’s output from January to April this year reached 33 million KVAh, exceeding the 31.5 million KVAh made during the same period in 2008. These figures are from the China Industrial Association of Power Sources and the National Bureau of Statistics.

Despite the generally optimistic outlook, makers admit they need to overcome pressing challenges to prop up the line.

The downturn in export sales has forced about 30 percent of companies out of the sector. An additional 50 percent transferred factories to lowcost areas such as Vietnam and India.

Many have reduced workforce by 40 to 50 percent. The majority uses only 40 percent of capacity.

In a bid to shore up support, especially for small operations, the China Electric Equipment Industrial Association is working to reinstitute the export tax rebate. It is also negotiating for financial assistance and the inclusion of high-end valve-regulated, lead-acid batteries for solar and wind power, and gel types into the list of products backed by the national government.

	The GM800-2-G from Guangdong Zhicheng Champion delivers 600 to 820Ah capacity and has a 15-year life span.

The second kind accounts for 40 percent of total output, and the last two collectively have a 10 percent share.

Valve-regulated variants, which include AGM and gel models, are expected to encroach into the other segments as more companies make the switch. These are increasingly being used in UPS and power tools. Many are also eyeing solar emergency systems and lighting, and medical devices.

A growing number of suppliers are devoting the bulk of production to valve-regulated types. Shenzhen Sway Battery Co. Ltd, which dedicates 90 percent of output to such models for UPS, telecom devices and power stations.

The maker plans to develop new units for solar and wind power systems. It also off ers acid- and explosion-resistant lead-acid models.

More than 100 companies produce gel types, which are expected to be in wider adoption in PV, power and field base stations.

Several have started research work on yet another variant, spiral valveregulated units. Using a special diaphragm and spiral plate, such models have an electrolyte that is 30 percent lower than other versions. They deliver a higher discharge rate and better high/low temperature performance.

Designed for faster charging, spiral valve-regulated batteries are suitable for meters, power tools, medical devices, standby power supplies and solar lights. Their flexible design allows for customization. The current selection covers 2, 4, 6 to 8V models with 2.5, 5, 8, 16, 25, 30 and 60Ah capacity.

Apart from structure and cap, leadacid batteries from China may be classified according to maintenance requirement, application and plate structure. There are models that need regular and less-frequency checks, and those that do not require upkeep at all.

Products categorized based on applications include start-up, traction, stationary and energy-saving units. As for plate structure, some are tubular and others use pasted platforms.

Of China’s more than 1,000 suppliers, 65 percent offer valve-regulated versions, 25 percent open variants and the rest acid- and explosion-resistant models. It is mostly large companies that focus on the second type, which is targeted at start-up and traction uses. Many of these operations also carry sealed batteries.

Regardless of kind, products support 2, 4, 6, 8, 10, 12, 24 and 36V rated voltage at any capacity.

Prices depend on the quantity of lead used, capacity, service life, and casing and terminal materials. The climbing cost of lead, which exceeded $1,700 per ton in June from about $1,000 in January, is expected to raise quotes in coming months.

The positive and negative plates, separator, electrolyte, safety valve and casing are the other major manufacturing inputs. About 80 percent of these are sourced locally, with the clapboard, gel and additive imported on request.

	The 6FM .2 from Guangdong Gemake is a valve-regulated lead-acid battery with .2Ah rated capacity and 12V rated voltage.

Complementing suppliers’ heightened focus on environment-friendly products are R&D eff orts directed toward models with more safety features, longer life span and higher reliability. Many are experimenting with new materials and techniques.

One such new input is the leadcalcium alloy plate, which resists erosion caused by electrolytes, thereby prolonging service life. Some use separators made of special multielement alloy to make the battery last 15 years. Jiangsu Shuangdeng Group Co. Ltd’s GFM series of valve-regulated lead-acid batteries uses dual-filtering acid mist filters that control the pressure level and prevent flames.

Special additives are being considered for the lead paste and electrolytes in line with efforts to increase the utilization rate of active material on the positive and negative plates. These inputs will also reduce the self-discharge rate.

Manufacturers such as Guangdong Zhicheng Champion Co. Ltd produce positive plates using die-casting technique instead of the widely adopted cast method. The former allows for a more compact and sealed design. To optimize structure, some makers are utilizing double or triple seals to achieve a blastand leak-resistant configuration.

Large players are working with universities and research institutes to explore new materials and techniques.

Shenzhen Sunnyway Battery Tech Co. Ltd has entered into a long-term partnership with the Haerbin Industry, Wuhan and South China Normal universities. The collaboration has yielded long life plate, gel and inner forming technologies.

Meanwhile, Jiangsu Shuangdeng has obtained more than 100 patents for its lead-acid batteries, including 12 for inventions. Guangdong Zhicheng Champion, which employs over 100 R&D personnel, has forged a cooperation agreement with Wuhan University and Huazhong University of Science and Technology.

	The SW25000 from Shenzhen Sunnyway weighs 31kg and supports 300 to 500Ah capacity.

Despite the high cost of complying with environmental protection regulations, more companies in China are implementing waste management programs to reduce, if not prevent altogether, lead pollution. Makers said technologies for lead mist and dust disposal, and vitriolic fog and water management have matured in recent years. Many adopt cartridge and wet filters to replace electrostatic precipitators and lower lead mist levels, respectively.

Guangdong Zhicheng Champion employs a gas filter film made of macromolecule substances to separate the caustic gas generated by the battery. Besides minimizing potential environmental hazards, it protects against flames.

Guangdong Gemake Electric Appliance Co. Ltd, meanwhile, has set up an automatic collection system for lead power and dust. The manufacturer also regulates acid mist and water deposits.

A major challenge for suppliers is the new 2006/66/EC directive on batteries and accumulators, which took eff ect in September 2008 and replaces the 91/157/EEC. The regulation requires member states to recycle a minimum 25 percent of products to the EU by Sept. 26, 2012 and 45 percent four years after.

Because of the huge investment needed to set up a recycling system, fewer than 10 makers in China currently have the capability to implement such a program for lead-acid batteries. Some companies, however, have established recycling operations in Tianjin and the provinces of Jiangsu and Hubei. While not yet compliant with the 2006/66/ EC, these facilities can achieve zero pollution emission and more than 96 percent recycle ratio.

To raise operation efficiency and battery quality, many are using advanced manufacturing equipment and undertaking stringent QC. Jiangsu Shuangdeng uses test machines from the US, Switzerland and the UK.

Production lines at Guangdong Gemake include semiautomated plate covering and a 140m assembly line said to be the longest in China. The company uses cast welding technology, atom absorption spectrometry, and testers for microcomputer charge and discharge, LCD vibration, inner resistance, voltage and big current discharge.

Shenzhen Sunnyway has infused more than $150,000 annually for the past several years to acquire electrochemistry equipment in a bid to further strengthen QC. Guanzhen Science & Technology Co. Ltd’s prepackaging tests cover high voltage, short circuit, functions, and microcomputer accumulator recycle charge and discharge.

More than 90 percent of companies comply with ISO 9001. Because of limitations in reducing lead dust and powder emission levels during production, only 20 percent of makers currently conform to ISO 14001.

Nearly 90 percent of mainland China’s supplier pool for this line is composed of local enterprises. The others are Taiwan-, US-, Japan- and South Korea-owned operations.

The major local companies include Shenzhen Center Power, Meimei, First-Power, Shenzhen Sunnyway, Zhejiang Narada, Wuhan Interpower, Guangdong Zhicheng Champion and Jiangsu Shuangdeng.

In general, makers with an annual capacity exceeding 1 million KVAh are considered large enterprises, while those capable of 500,000 to 1 million KVAh are midsize. Small players can turn out below 500,000KVAh each year.

Some of the bigger operations can produce their own materials, allowing them to control quality and delivery better than smaller counterparts.

Most companies can be found in the provinces of Guangdong, Hubei, Zhejiang and Jiangsu. The first accounts for 20 and 35 percent of China’s total lead-acid battery output and exports, respectively. Makers there leverage the area’s comprehensive supply chain and logistics facilities. Their export-driven business model, however, has made them more vulnerable to the global financial crunch than enterprises located in other provinces, whose overseas shipments average 20 percent of turnout.

The main export markets are Europe, India, North America, Southeast Asia, Africa and the Middle East.