1. Maureen Murphy of Hammond Expander Group in Hammond, IN
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matt Raiford, Ph. D., Tim Ellis, Ph. D., David Prengeman, Ph. D. of RSR Technologies in Dallas, TX
Maureen Murphy of Hammond Expander Group in Hammond, IN

2. Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

3. Charge Acceptance in Lead Acid Batteries (LAB)s
PbSO4 → Pb2+(aq) + SO42-(aq)
Ksp = 1.32 × 10-8
Three major issues occurring related to charge acceptance.
Gassing of O2 and H2.
Poor intraplate conductivity.
Dissolution of PbSO4
Increasing battery plate conductivity in LABs would allow more rapid movement of energy.
Formation of sulfate is the fast step
DCA PROBLEM
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

4. SUPERSOFT-ULTRA® Secondary Lead
Work by Lan T. Lam and others in Journal of Power Sources 195, demonstrated that certain impurities in lead (Pb) had more influence on gassing than others. 85% of batteries are made from recycled (secondary) lead in the West.
RSR Technologies removed several of the gassing elements in a high purity secondary lead to low levels which is called SUPERSOFT-ULTRA®.
Sb, As, Cd, Cr, Co, were reduced to <0.1ppm.
Mn, Te, and Se were reduced to <0.2ppm
Ni and Sn were reduced to <1ppm
Cu, Zn, and Fe were reduced to 2ppm or less.
Lam, L. T. J. Power Sources 2010, 195, 4494.
NEW APPLICATION FOR SECONDARY LEAD; MINIMIZE FAILURE FROM H2O LOSS
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

5. Gassing and Charge Retention for Float Application
Gassing Rate (Float at 25◦C and 2.27 Volts)
Charge Retention (Self Discharge During Storage at 25◦C)
Days
%Life
POWER BACKUP DUTY-International
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

6. Accelerated Float Life at 65◦C
HIGH AMBIENT TEMP → AUTOMOTIVE/GRID STORAGE
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

7. Designing Active Materials
“Hybrid (48V) and Heavy Cycling”
“Stop/Start (12V)”
“Telecommunications”
“Industrial”
“UPS”
“SLI Replacement”
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

8. Microstructural Control through Electrolyte Addition
EFFECTS ON NEGATIVE ACTIVE MATERIAL
Micro/nanostructure of the sulfate greatly influences:
Dissolution rate
Cold Crank Amps and other important performance standards
DCA
Active material utilization
CRYSTAL STRUCTURE DRIVES PROPERTIES
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

9. DCA Improvement by Microstructural Control
Microstructure control could improve intraplate conductivity.
Three major pathways:
Grain size control to inhibit Ostwald ripening.
Crystal structure and texture considerations.
Kinetics of the reaction must be improved by additive chemistry.
CRYSTAL STRUCTURE DRIVES PROPERTIES
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

10. Intraplate Conductivity Enhancement
SUPERSOFT-ULTRA®
Microalloying utilizes a Intraplate conductivity effect to create preferential growth of highly conductive PbO2 crystal conglomerates.
The resulting increase in conductivity is supplemented by further elemental additions into the lead, creating a more conductive intraplate network.
Enhancements in conductivity must be weighed against changes in water loss.
High Antimony Alloy
CRYSTAL STRUCTURE DRIVES CONDUCTIVITY
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016 10

11. Microstructural Differences in Crystal Growth
Control
SUPERSOFT-HYCYCLETM
Control and SUPERSOFT-HYCYCLETM show similar crystallite structure.
Aspect ratio of control is 1:2.5
Aspect Ratio of SUPERSOFT-HYCYCLETM is 1:4.1
Similarities in cured paste, used paste shows a difference in formed paste.
MINOR ELEMENTS CHANGE STRUCTURE
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

12. New Soft Pb Alloy: SUPERSOFT-HYCYCLE™
C and C20 testing of SUPERSOFT-ULTRA® showed similar performance to typical primary leady oxide.
C and C20 increased five percent in the SUPERSOFT- HYCYCLETM(PATENT PENDING(PP)).
MAXIMIZE THE EFFECT OF BENEFICIAL ELEMENTS
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

13. Joint Program with Hammond Group: Initial MicroHybrid Cycle Testing with Secondary Lead
MICROCOMPOSITION CONTROL HELPS
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

14. Cycling Comparison from Collaborators
ENHANCE PERFORMANCE FROM SUPERSOFT-HYCYCLETM
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

15. Improvements to Grid Alloys
Existing improvements on grid corrosion have created a good platform for better active material.
The use of carbon-enriched NAM plates has resulted in new limiting factors in HRPSoC performance.
Cathodic corrosion
PAM shedding and molting
Especially at high temperatures
Thinner grids with same properties
New grids for higher temperature performance and cathodic corrosion.
GRAIN STRUCTURE ENGINEERING
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

16. Materials Improvement by Design
RSR 009+ alloy has higher strength and hardness than RSR PbCaSn after prolonged exposure to 70 °C.
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| Da September 15, 2016

17. NorthStar Alloy-Increasing Float Life
High Silver Alloy
+25 ppm Silver Alloy
Low Silver Alloy
Calcium Alloy
TRACE ELEMENT CONTROL IS KEY
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

18. 100% DOD Float Cycling Battery Testing with Silver Alloy
High Silver
Calcium
MICROSTRUCTURAL ENGINEERING GREATLY INHIBTS CORROSION
Calcium Alloy
Silver Alloy
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

19. Benefits of Secondary Lead
Recycled SUPERSOFT-ULTRA® lead can perform as well as even the highest purity primary lead when used in critical applications. 85% of batteries in the West are from recycled lead.
The gas causing elements such as Te, Se, Ni, Sb, As, Co, Mn, Cr, Fe, and Cu must be removed to levels about 10 times lower than normal secondary lead specifications.
Silver and Bismuth do not have to be removed and present virtually no problem in the use of this lead for VRLA and low gassing batteries.
Lead for active material can be further improved for higher cycle life and energy density, and intensive study of the morphology and electrochemical behavior has lead to SUPERSOFT-HYCYCLETM (PATENT PENDING).
Have installed a battery tester (320 channels) to further support secondary soft lead development.
COMPOSITION OPENS IMPROVEMENTS FOR ACTIVE MATERIALS
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

20. Still More Improvements Possible!
Highly Refined and Alloyed SUPERSOFT-ULTRA® Recycled Lead for Critical Applications
Matthew Raiford| September 15, 2016

21. Thank you for your kind attention.
Matthew Raiford
RSR Technologies
4828 Calvert St.
Dallas, TX 75081
(469)