Lead Oxide (PbO) is the main material used for the preparation of the active material for the positive and negative electrodes in the lead acid battery where the electrochemical reaction that provides the electrical energy of the battery takes place. The particle size distribution and surface area characteristics of the lead oxide play a major role in the electrical performance of the completed battery. The two most commonly used processes to manufacture PbO in the lead acid battery industry are the Barton pot and the Ball mill processes. These two processes produce oxides that differ in particle size distribution, particle shape and surface area. It is generally accepted that the Ball mill process produces an oxide with a smaller mean particle size with a higher surface area and better initial electrical performance than the Barton pot process to the detriment of an initial higher capital and running cost. The study showed that it is possible to improve the surface area and particle size distribution characteristics of Barton pot oxide, by subsequently hammer milling the oxide particles before the paste manufacturing process. The results showed that there was an initial reduction in the particle size with an increase in the surface area. This increased the electrochemical performance in terms of the high rate discharge. However, further hammering of the oxide reduced the average particle size only slightly with little change in the surface area and a reduction in the electrochemical performance. The study showed that an improvement in Barton pot oxide can be achieved with a hammering of the oxide in order to obtain a uniform particle size with improved surface area and an improved high rate performance of the electrochemical cells made with such an oxide. As a comparison, the particle size and surface area characteristics of Ball mill lead oxide subjected to the hammer milling process was also studied. The results showed a similar effect to the Barton pot oxide on the particle size distribution. However, there was no appreciable change in the surface area due to the hammer milling process.

One of the technical advances made by the lead-acid battery industry in the field of portable power supply was the development of the valve regulated lead-acid battery (VRLA). This battery reduced the necessity for periodic servicing in terms of having to replenish the cells with distilled water. Further, this new type of battery can now be installed near sensitive electronic equipment without the danger of acid spill or dangerous fumes being emitted. In addition, longer service performance is achieved in terms of life cycle capacity, when compared to the conventional flooded type batteries. However, the new type of battery requires the manufacturing of high precision electrodes and components with low tolerances for error. In order for the manufacturers to produce such a premium product, a thorough understanding of the electrochemistry of the inner components is necessary. None of the South African lead-acid battery manufacturers are currently making VRLA batteries to supply a very competitive global market, where a large range of sizes and capabilities are available. In order to introduce the VRLA battery into such a competing market in South Africa, a niche area for its application was identified in order to establish the viability of manufacturing such a battery locally. This is done by integrating the VRLA concept into an existing battery, such as the miners cap lamp (MCL) battery. Its application is specific with well-defined performance criteria in a relatively large consumable market in the South African mining industry. The study looked at various components within a local manufacturing environment that required a better understanding and modification of the processes to build VRLA MCL batteries. This included a detailed study of the manufacturing processes of the positive electrode. The study involved the investigation of the types of grid alloys used, the type of electrode design, such as tubular or flat plate, the addition of redlead to the paste mixing process and subjecting the batteries to accelerated life cycle testing. A better understanding of the oxygen recombination cycle was also performed in order to evaluate the correct use of certain design criteria in the manufacturing process. This included the study of the pressure release valve and the type of positive electrode used. The study also looked at developing an inexpensive analytical technique to evaluate the porosity of cured and formed electrodes using a glycerol displacement method. The monitoring of the state of health (SoH) of VRLA batteries on a continuous basis is an important parameter in unique applications such as remote power supply. A device was developed to monitor the SoH of VRLA batteries on a continuous basis. The working principle of the device was tested on a MCL VRLA battery. With the development of other types of VRLA batteries for specific applications such as in stand-by power supplies, the monitoring device would then be integrated in the battery design.