Electro Gel

ELECTRO GEL is a viscous synthetic polymer gel electrolyte FREE from SILICA. It is soluble in water, acid and other ionic solvents. It is manufactured using specialty chemicals and proprietary process for the first time. ELECTRO GEL is a revolutionary product for the battery industry; it is recommended only for AGM (Absorptive Glass Mat) batteries. 

The two major problems related to lead acid batteries are CORROSION and

SULPHATION. Unless and until non-corrosive electrolyte is developed for the batteries, these two problems continue to limit the life and performance of the batteries. It is therefore very important to minimize the negative role of sulphuric acid as an electrolyte for the batteries. ELECTROGEL is developed to meet the challenges posed by highly corrosive sulphuric acid for battery.

ELECTRO GEL offers following major advantages to battery:

• Protects positive plates from corrosion. 
• Protects negative plates from sulfation. 
• Protects plates from external and internal heat. 
• Protects active materials from shedding. 
• Minimum water loss. 
• Protection against deep discharges. 
• Longer life battery. 
• Environment friendly battery. 
• All weather battery.

 ELECTRO GEL when filled into the new battery along with sulphuric acid utilizes the power from the charged plates and turns into a viscous gel within 3 to 4 hours (in the case of formed plate batteries) depending on the size of the battery. 

On charging the battery, the viscous gel slowly turns into a compact protective film on each battery plate. The protective film so formed prevents direct attack of ionic sulphate ions on the battery grids. The compact film also helps to check the volumetric expansion/contraction of active materials during charge/discharge process thereby shedding of active materials is prevented. Migration of corrosion by products from positive plates is eliminated by the film. The protective film also checks the heat generation during charge/discharge process. Dynamic and static sulphation are best prevented by the film, as after film formation negative plates active materials remain free from contamination.

 ELECTRO GEL for GREEN plate battery:

1. Prepare a mixture of ELECTRO GEL and sulphuric acid (20% ELECTRO GEL+ 80% SULPHURIC ACID of 1350 S.G for automotive battery and 1400 S.G. for industrial battery). Final S.G. of mixture will be 1260 for automotive battery and 1290 for industrial battery. ELECTRO GEL and acid must be thoroughly mixed.
2. The mixture is then filled into each cell up to plate height. Leave the battery for 24 hours in idle condition. 
3. After 24 hours, carry out normal charging of the battery, preferably with 7 to 8% of the battery rated capacity. As the charging of the battery progresses, the liquid mixture begins to turn into a viscous polymer. At the same time the plates also get charged. Further charging converts viscous material into a solid protective film on each plate and covers the whole of the cell.
4. Charging should be continued till you find that online volts reaches 16.5 volts for a 12 volts batteries, for 6 volts it will be 9.5 volts and for 2 volts cells ,it will be 3.5 volts.
5. At the end of charge there will not be any free liquid in the cell, except a small quantity of free water at the bottom of each cell. Most liquid that was filled initially will get converted into a polymer film formation.

ELECTRO GEL for a formed/dry charged plate’s battery:

1. Filling of ELECTRO GEL + ACID mixture into a new battery having formed plates should be done carefully to avoid excessive heat and gas generation. We strongly recommend those batteries to be filled with mixture must therefore be immersed into cold water bath unto plate height. Water bath temp. Should be 20 to 25 degree centigrade or less. 
2. Fill the mixture unto plate height only. Leave the batteries into water bath for 3 hours to cool down. 
3. Take out the batteries from water bath after 3 hours and leave them outside for further cooling for another 6 to 9 hours. If topping up is required, add mixture to cover unto plate height. (If water bath is not used then gel mixture will flow out of battery due to heat and gas).
4. Cooled batteries are then put to charging using either constant current or constant voltage charger. Normal charging procedure is followed. 
5. During charging process if topping up is required, add the mixture. Fully charged battery be removed from machine, allow to cool down and topped up with acid.
6. During battery servicing/maintenance topping be done with distilled water.